GARDNER DENVER
3–1–614

2nd Edition
April, 1998

PLUNGER PUMPS
TRIPLEX MODELS
TQB (GD25T)
TQW (GD45T)
TQC (GD50T)
TAC (GD60T)
TDD (GD100T)
TAE (GD150T)
TDE (GD180T)
TFE (GD200T)

QUINTUPLEX MODEL
QBX (GD135Q)

OPERATING AND
SERVICE MANUAL
 MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER
PARTS AND SUPPORT SERVICES

Gardner Denver
and OPI
genuine pump parts are gency parts by direct access to the Gardner Denver
manufactured to original tolerances and designed for Machinery Inc. Master Distribution Center (MDC) in
optimum dependability. Design and material innova- Memphis, Tennessee.
tions are the result of years of experience with Your authorized distributor can support your Gardner
hundreds of different pump applications. Reliability in Denver and OPI pump needs with these services:
materials and quality assurance are incorporated in our
genuine replacement parts. 1. Trained parts specialists to assist you in select-
ing the correct replacement parts.
Your authorized Gardner Denver and OPI distribu- 2. Repair and maintenance kits designed with the
tor offers all the backup you’ll need. A worldwide necessary parts to simplify servicing your pump.
network of authorized distributors provides the finest
product support in the pump industry. Authorized distributor service technicians are factory–
trained and skilled in pump maintenance and repair.
Your local authorized distributor maintains a large in- They are ready to respond and assist you by providing
ventory of genuine parts and he is backed up for emer- fast, expert maintenance and repair services.

For the location of your local authorized Gardner Denver and OPI distributor refer to the yellow pages
of your phone directory or contact:
Distribution Center: Factory:
Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: (217) 222–5400
Phone: (901) 542–6100 Fax: (217) 223–5897
Fax: (901) 542–6159

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Pump MODEL and per unit, quantity is indicated in parenthesis. SPECIFY
SERIAL NUMBER (see nameplate on unit). The Serial EXACTLY THE NUMBER OF PARTS REQUIRED.
Number is also stamped on top of the cylinder end of
the frame (cradle area). DO NOT ORDER BY SETS OR GROUPS.

All orders for Parts should be placed with the near- To determine the Right Hand and Left Hand side of a
est authorized distributor. pump, stand at the power end and look toward the fluid
end. Right Hand and Left Hand are indicated in paren-
Where NOT specified, quantity of parts required per thesis following the part name, i.e. (RH) & (LH), when
pump or unit is one (1); where more than one is required appropriate.

3–1–614 Page i
 FOREWORD

Gardner Denver
and OPI
pumps are the result of advanced engineering and skilled manufacturing. To be assured
of receiving maximum service from this machine the owner must exercise care in its operation and maintenance.
This book is written to give the operator and maintenance department essential information for day–to–day opera-
tion, maintenance and adjustment. Careful adherence to these instructions will result in economical operation and
minimum downtime.

Danger is used to indicate the presence of a hazard which will cause severe personal
injury, death, or substantial property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard which can cause severe person-
al injury, death, or substantial property damage if the warning is ignored.

Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.

Notice is used to notify people of installation, operation or maintenance information

which is important but not hazard–related.

For Part List information, see:

Model Parts List

TQB (GD25T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1–517

TQW (GD45T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1–518
TQC (GD50T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1–514
TAC (GD60T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1–520
TDD (GD100T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1–530
TAE (GD150T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1–526
TDE (GD180T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1–527
TFE (GD200T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1–528
QBX (GD135Q) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1–531

3–1–614 Page ii
 TABLE OF CONTENTS

Maintain Pump Reliability and Performance with Genuine Gardner Denver Parts and
Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Instructions For Ordering Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

List of Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Section 1, Danger Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Section 2, Operating and Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Suggested Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Section 3, Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Crankcase Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Plunger Packing Lubrication Recommendation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gardner Denver Horizontal Pump Recommended System Layout for Proper Performance . . . 26
Net Positive Suction Head Required (NPSHR) at Fluid Cylinder Suction Connection with
Suction Stabilizer and Discharge Pulsation Dampener Installed . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Correction Chart for Temperature or Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Viscosity Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Section 4, Trouble–Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Section 5, Rebuilding Data and Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Rebuilding Data For TQB (GD25T) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 – 37
Rebuilding Data For TQW (GD45T) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 – 40
Rebuilding Data For TQC (GD50T) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 – 43
Rebuilding Data For TAC (GD60T) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 – 47
Rebuilding Data For TDD (GD100T) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 – 50
Rebuilding Data For QBX (GD135Q) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 – 53
Rebuilding Data For TAE (GD150T) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 – 56
Rebuilding Data For TDE (GD180T) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 – 59
Rebuilding Data For TFE (GD200T) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 – 62
Fastener Torques Unless Otherwise, Specified – All Pumps (Grade 5) . . . . . . . . . . . . . . . . . . . . 63

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page

3–1–614 Page iii

 INDEX

Clamped Seat Valves . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lubricator, Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Connecting Rods and Crossheads . . . . . . . . . . . . . 20
Covers and Guards, Danger Notice . . . . . . . . . . . . . . 2 Moving and Lifting Equipment, Danger Notice . . . . . 2

Crankcase Oil Requirements . . . . . . . . . . . . . . . . . . 24

Net Positive Suction Head Required . . . . . . . . . . . . 27
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crossheads and Connecting Rods . . . . . . . . . . . . . 20 OPERATING AND MAINTENANCE INSTRUC-
TIONS, SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . 7
DANGER NOTICES, SECTION 1 . . . . . . . . . . . . . . . 1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Danger Notices
Ordering Instructions, Repair Parts . . . . . . . . . . . . . . i
Covers and Guards . . . . . . . . . . . . . . . . . . . . . . . . 2
Equipment Moving and Lifting . . . . . . . . . . . . . . . 2 Packing, Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flammable, Hot, Cold or Corrosive Fluid Packing Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Periodic Maintenance Schedule . . . . . . . . . . . . . . . . 11
Hammer Lug Fasteners . . . . . . . . . . . . . . . . . . . . 1
Plunger Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
High Pressure Liquid Jetting, Blasting and
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Plunger Packing Lubrication Recommendation
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rock Drill Lubricants . . . . . . . . . . . . . . . . . . . . . . 25
Pressurized Pump Systems . . . . . . . . . . . . . . . . . 3
Steam Cylinder Oils . . . . . . . . . . . . . . . . . . . . . . . 25
Valve Seat Pulling . . . . . . . . . . . . . . . . . . . . . . . . . 2
Plungers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wedge Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disc Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressurized Pump Systems, Danger Notice . . . . . . 3
Equipment Moving and Lifting, Danger Notice . . . . . 2
REBUILDING DATA AND TORQUES,
Flammable, Hot, Cold or Corrosive Fluid Pumping, SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Danger Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rebuilding Data and Torques
Fluid Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fastener Torques Unless Otherwise Specified
Fluid End Corrosive Attack . . . . . . . . . . . . . . . . . . . . 10 All Pumps (Grade 5) . . . . . . . . . . . . . . . . . . 63
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii QBX (GD–135Q) Pumps . . . . . . . . . . . . . 51 – 53
TAC (GD–60T) Pumps . . . . . . . . . . . . . . . 44 – 47
Hammer Lug Fasteners, Danger Notice . . . . . . . . . . 1
TAE (GD–150T) Pumps . . . . . . . . . . . . . . 54 – 56
High Pressure Liquid Jetting, Blasting and Cleaning, TDD (GD–100T) Pumps . . . . . . . . . . . . . . 48 – 50
Danger Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TDE (GD–180T) Pumps . . . . . . . . . . . . . . 57 – 59
Hydraulic Puller, Danger Notice . . . . . . . . . . . . . . . . . 2
TFE (GD–200T) Pumps . . . . . . . . . . . . . . 60 – 62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TQB (GD–25T) Pumps . . . . . . . . . . . . . . . 35 – 37
TQC (GD–50T) Pumps . . . . . . . . . . . . . . . 41 – 43
Lifting and Moving Equipment, Danger Notice . . . . . 2
TQW (GD–45T) Pumps . . . . . . . . . . . . . . 38 – 40
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Repair Parts, Ordering Instructions . . . . . . . . . . . . . . i

3–1–614 Page iv
 INDEX (Continued)

Seat Valves TROUBLE–SHOOTING, SECTION 4 . . . . . . . . . . . 30

Clamped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve, Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tapered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Valve Seat Pulling, Danger Notice . . . . . . . . . . . . . . . 2
SERVICE INSTRUCTIONS, SECTION 3 . . . . . . . . 14
Valves
Starting a New Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Stuffing Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Wing Guided and Severe Duty . . . . . . . . . . . . . 15
Suction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Viscosity Conversion Table . . . . . . . . . . . . . . . . . . . . 29
Suggested Periodic Maintenance Schedule . . . . . . 11 Viscosity or Temperature, Correction Chart . . . . . . 28
System Layout, Horizontal Pump . . . . . . . . . . . . . . . 26
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page
Tapered Seat Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wedge Puller, Danger Notice . . . . . . . . . . . . . . . . . . . 2
Temperature or Viscosity, Correction Chart . . . . . . 28 Wing Guided and Severe Duty Valves . . . . . . . . . . . 15

LIST OF ILLUSTRATIONS

Figure # Description Page

Figure 1 Rear Sectional View of Triplex Power End Showing Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 2 Top Sectional View of Quintuplex Power End Showing Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 3 Sectional View of Triplex and Quintuplex Plunger Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3–1–614 Page v
SECTION 1
DANGER NOTICES

reread periodically by both operators and maintenance

personnel to refresh their memories in safe procedures
and practices.
Read and understand the following DANGER Keep in mind that full operator attention and alertness
NOTICES before moving or operating the pump or any are required when operating high pressure pumping
pump package unit equipment. equipment. Operators should not begin or continue op-
erations when tired, distracted or under the influence of
Reciprocating pumps are machines capable of produc- alcohol or any type of prescription or nonprescription
ing high fluid pressures and flow rates and are de- drugs.
signed to be used with proper care and caution by
trained, experienced operators. TO AVOID PER- The timely replacement of expendable parts and any
SONAL INJURY, DEATH AND/OR EQUIPMENT other worn or damaged parts can prevent equipment
DAMAGE, READ AND THOROUGHLY UNDER- damage and possible injury. The original parts used in
STAND THE FOLLOWING DANGER NOTICES Gardner Denver pumps are designed and tested to ex-
PLUS THE ENTIRE OPERATING AND SERVICE acting standards to provide high quality performance
MANUAL BEFORE ATTEMPTING TO MOVE OR and durability. Your best insurance in maintaining
OPERATE THE PUMP. Contact a Gardner Denver these characteristics is to use genuine Gardner Denver
Machinery service representative if you are unable to replacement parts.
comply with any of the danger notices or procedures
described in these documents. A broad range of danger notices are covered on these
pages, however, they cannot substitute for training, ex-
Closely examine the data plate upon pump delivery to perience and common sense in the safe operation of
become thoroughly familiar with the operating limits for high pressure pumping equipment.
this pump model. The pump must never be operated
at speeds, pressures or horsepower exceeding the HAMMER LUG FASTENERS
maximum values shown on the data plate or at
speeds below the minimum shown. Failure to ob-
serve the operating limits shown on the data plate
could result in personal injury, death, and/or On pumps or pump package units equipped with ham-
equipment damage and will void the warranty. Al- mer lug connectors and/or hammer lug valve covers
terations to the pump, or application of the pump out- the following precautions must be observed to avoid
side the data plate limits, must not be made without personal injury, death and/or equipment damage due
Gardner Denver Machinery written approval together to contact with the hammer, hammer bar, broken parts
with a new data plate, as dangerous operating condi- from the hammer, hammer bar or lugs or other objects
tions could result. propelled by hammer blows. When tightening or loos-
ening hammer lug connectors and valve covers, opera-
THE DANGER NOTICE AND DATA PLATES PRO- tors or maintenance personnel should:
VIDED ON THE EQUIPMENT MUST NOT BE RE-
MOVED, PAINTED OVER, HIDDEN OR DEFACED. S Inspect the hammer, hammer lugs and hammer
They must be replaced if they become damaged or un- bar, if one is used, to insure they are all in good
readable. Provisions should be made to have the fol- condition. Replace any of these parts which are
lowing written danger notices plus the pump operating cracked, damaged or badly worn.
and service manual readily available to operators and S Wear safety shoes and goggles.
maintenance personnel. In addition, copies of all pump
system accessory component (e.g. pressure relief S Alert other personnel to move away from the
valve, pulsation dampener, suction stabilizer, engine, area.
electric motor, etc.) operating and service manuals S Check to insure they have safe footing.
should be readily available for operator and mainte-
S Fully engage the hammer bar, if one is used, to
nance personnel use. Read and follow all the precau-
prevent it from disengaging violently from the
tions and instructions contained in these manuals. If
cover as a blow is struck.
any of these documents are lost or become illegible
they must be replaced immediately. The danger no- S Wipe their hands and the hammer handle and
tices plus the operating and service manuals should be maintain a firm grip on the handle to avoid los-

3–1–614 Page 1
 ing control of the hammer while swinging and COVERS AND GUARDS
striking.
S Carefully swing the hammer to avoid striking
themselves, another person and objects other
than the targeted lugs or hammer bar.
S Avoid swinging the hammer above shoulder
Personal injury, death, and/or equip-
height. ment damage can result from contact
with moving parts. All moving parts
VALVE SEAT PULLING must be equipped with covers and
guards. All covers and guards must
be securely positioned at all times
when the unit is in operation.
The following precautions must be observed by opera-
tors and maintenance personnel to avoid personal inju-
ry, death and/or equipment damage from contact with
the puller, hammer, wedge or broken parts from these Covers and guards are intended to not only protect
components when using either a hydraulic or wedge against personal injury or death, but to also protect the
valve seat puller. Operators or maintenance personnel equipment from foreign object damage.
should:

Hydraulic Puller EQUIPMENT MOVING AND LIFTING

S Wear safety shoes and goggles.

S Chain or tie the jack down as it will jump violently
when the valve seat disengages from the valve Heavy equipment including pumps, pump package
deck. units and components should only be moved or lifted
by trained, experienced operators, who are physically
S Check to insure the pressure applied by the hy- and mentally prepared to devote full attention and alert-
draulic pump does not exceed the hydraulic ness to the moving and lifting operations. An operator
ram maximum pressure rating. should be fully aware of the use, capabilities, and
Wedge Puller condition of both the equipment being moved and the
equipment being used to move it.
S Grind off any mushroomed material from the
wedge before use.
S Inspect the hammer and wedge to insure they
are in good condition. Replace any of those
parts which are cracked, damaged or badly Failure to follow safe and proper
worn.
pump, pump package or component
S Wear safety shoes and goggles. lifting or moving procedures can lead
S Check to insure they have safe footing. to personal injury, death and/or
equipment damage from shifting, fal-
S Fully engage the wedge to prevent it from dis-
engaging violently from the cover as a blow is ling or other unexpected or uncon-
struck. trolled equipment movements.
S Wipe their hands and the hammer handle and
maintain a firm grip on the handle to avoid los-
ing control of the hammer while swinging and Make sure the hoist, lift truck, ropes, slings, spreader,
striking. or other lifting equipment you are using is in good condi-
S Carefully swing the hammer to avoid striking tion and has a rated lifting capacity equal to or greater
themselves, another person and objects other than the weight being lifted. Lifting devices must be
than the targeted wedge. checked frequently for condition and continued confor-
mance to rated load capacity. They should then be
S Avoid swinging the hammer above shoulder tagged with the inspected capacity together with the
height. date of inspection.

3–1–614 Page 2
Fully assembled pumps and pump package units are PRESSURIZED PUMP SYSTEMS
heavy and should only be moved using the specified
lifting lugs or attachments.

Many individual components have lifting eyes or

lugs which must not be used to lift assemblies, as Fluids under high pressure can pos-
they are designed to bear the weight of the compo- sess sufficient energy to cause per-
nent only. sonal injury, death and/or equipment
damage either through direct contact
Before lifting the individual component check to insure with escaping fluid streams or by con-
the lifting attachment is firmly secured to the compo- tact with loose objects the pressur-
nent with undamaged, properly torqued fasteners,
sound welds, or other secure attachments. Examine ized fluid propels.
the lifting eyes, lugs, slots, holes or other projections to
insure they are not cracked, otherwise damaged or
badly worn. The repair of existing or addition of new Operating a pump against a blocked or restricted dis-
welded lifting eyes, lugs or other projections should charge line can produce excessive pressures in the en-
only be performed by experienced, qualified welders. tire discharge system, which can damage or burst dis-
charge system components.
Package units should be lifted with spreaders con-
nected to the lifting attachments normally built into the
package unit support skid. Packages too large to lift ful-
ly assembled should be separated into smaller loads.
Never operate a pump without a prop-
erly sized pressure relief valve lo-
For these smaller loads the lifting devices should be cated in the flowing discharge line im-
fastened to the lifting attachments normally built into mediately adjacent to the pump dis-
the individual motor, engine, pump or transmission/ charge connection.
torque converter, or their separate support skids.

When lifting subassembled components, for example The relief valve should be placed in the flowing dis-
a suction stabilizer attached to suction piping or a dis- charge line and not at the opposite end of the discharge
charge pulsation dampener attached to a strainer cross manifold in a dead end connection. The dead end may
and piping, use special lifting slings designed to safely become clogged with solid material carried in the fluid,
support the combined weight of the components. which could prevent proper relief valve operation.

If a crane or hoist is being used to lift large components

or assemblies, one or more persons should assist the
operator from the ground with guide lines attached to
the equipment being moved to properly position it and Never place a shut–off valve or any
prevent uncontrolled movement. other component between the pump
discharge connection and the pres-
When you start to lift a pump, package unit, subassem- sure relief valve.
blies or individual components and you observe the
equipment is tilting, or appears unbalanced, lower the
equipment and adjust the lifting device to eliminate
these improper lifting conditions before proceeding to Make sure the pressure relief valve is installed so any
move the equipment. pressurized relief discharge from the valve is directed
away from possible contact with people or equipment.
The relief valve must be set to relieve at a pressure
It is poor practice and dangerous to allow the equip- equal to or below the maximum pressure values shown
ment to pass over or close to your body or limbs. Be on the pump data plate. However, if a component is
prepared to move quickly out of danger if equipment used in the discharge system with a lower rated pres-
starts to fall, slip or move unexpectedly toward you. sure capability than that listed on the pump data plate,

3–1–614 Page 3
the pressure relief valve must be set to relieve at a pres- Proper stuffing box packing selection is important for
sure equal to or below the rated capability of the lowest safe pump operation. Contact a Gardner Denver Ma-
rated component. chinery service representative for assistance in select-
ing the proper packing before beginning operation.
Before starting the pump every time, check to in-
sure: Before starting the pump the first time and periodically
thereafter check the pump, suction and discharge sys-
S The pressure relief valve is in good operating tem fastener torques versus the values listed on page
condition and has been set to the proper relief 12 to insure proper tightness. Over and under torquing
pressure. can damage threaded pipes, connections and fasten-
ers, which may lead to component damage and/or fail-
S Any pipe line used to direct pressurized relief
ure. Replace all components found to be damaged or
flow to another location, such as a collecting
defective. On pumps equipped with stuffing boxes, the
tank, is not blocked.
gland must be engaged by at least three (3) threads to
S The discharge system is not blocked and all the hold the discharge pressure of the pump.
discharge line valves are open.
Check all fluid end discharge system components
including pipe, connections, elbows, threads, fas-
teners, hoses, etc., at least once every six months
to confirm their structural adequacy. With time, Do not attempt to service, repair, ad-
wear, corrosion and fatigue can reduce the strength of just the plunger packing or otherwise
all components. Magnetic iron and steel components work on the pump while the unit is op-
should be checked with magnetic particle or dye pene- erating. Shut off the pump drive mo-
trate crack detection equipment. Nonmagnetic materi-
als should be checked for cracks with dye penetrants.
tor or engine and relieve the fluid
All metallic components should also be visually pressure in the pump suction and dis-
checked during these inspections for signs of corro- charge systems before any work or
sion. If a component shows evidence of cracking or investigation is performed on the
loss of material due to corrosion it must be replaced pump or pump systems.
with a new part.

Continually monitor suction and discharge hose as-

semblies when the pump is operating for leakage, kink- Block the crankshaft from turning and make certain that
ing, abrasion, corrosion or any other signs of wear or all pump drive motor or engine start switches or starter
damage. controls are clearly tagged with warnings not to start
the pump while repair work is in process.
Worn or damaged hose assemblies should be re-
placed immediately. At least every six months ex- Whenever the pump is operating, continually monitor
amine hose assemblies internally for cut or bulged the entire suction, discharge and pump lubricating sys-
tube, obstructions and cleanliness. For segment style tems for leaks. Thoroughly investigate the cause for
fittings, be sure that the hose butts up against the nipple leakage and do not operate the pump until the cause
shoulder, the band and retaining ring are properly set of the leak has been corrected. Replace any parts
and tight and the segments are properly spaced. which are found to be damaged or defective. When a
Check for proper gap between nut and socket or hex gasketed joint is disassembled for any reason, discard
and socket. Nuts should swivel freely. Check the lay- the used gasket and replace it with a new, genuine Gar-
line of the hose to be sure that the assembly is not dner Denver gasket before reassembling the joint.
twisted. Cap the ends of the hose with plastic covers Due to the high working pressures contained by the
to keep them clean until they are tested or reinstalled fluid cylinder, discharge manifold and discharge piping,
on the pump unit. Following this visual examination, welding on these components is not recommended. If
the hose assembly should be hydrostatically tested, on welding on the discharge system cannot be avoided,
test stands having adequate guards to protect the oper- only experienced, qualified welders should be used. In
ator, per the hose manufacturer’s proof test procedure. addition, the welded part should be hydrostatically
proof tested in the shop with water or hydraulic fluid to
Fluid end component inspections should be per- one and one half times maximum discharge system
formed more frequently than every six months if working pressure, with no observable fluid leakage, be-
pressures above 2500 psi are used in the dis- fore the part is reinstalled in the pump system.
charge system or if corrosive, flammable or hot
(over 110_ F) fluids are being pumped. In summary, high pressure fluid streams can possess

3–1–614 Page 4
sufficient energy to cause personal injury, death and/or times when the pump is operating. If the pumped
equipment damage. These results can occur either fluid releases harmful, explosive or flammable va-
through direct contact with the fluid stream or by con- pors the covers must be vented to conduct the
tact with loose objects the fluid stream has propelled, fumes away from the pump unit to a nonhazardous
if the pump system is improperly used, or if the fluid is area.
misdirected, or allowed to escape from defective or im-
properly maintained equipment. Before beginning pumping operations or starting the
pump power source (whether an engine or electric mo-
FLAMMABLE, HOT, COLD OR CORROSIVE FLUID tor) check the atmosphere all around the pumping site
PUMPING for the presence of flammable or explosive vapors. Do
not begin operation and stop ongoing operation if flam-
mable or explosive vapors are detected. Hot surfaces,
sparks, electric current or engine exhaust could ignite
flammable or explosive vapors. Each engine used as
a power source on pumping units where flammable or
Extreme caution must be exercised explosive vapors could form should be equipped with
by trained and experienced operators an air inlet shut–off. If flammable or explosive vapors
when flammable, hot, cold or corro- are present in the pumping site atmosphere, an engine
could continue to run on these vapors even after the en-
sive fluids are being pumped, in order gine fuel line is shut–off if an air inlet shut–off is not
to avoid personal injury, death and/or used.
equipment damage due to explosion,
In addition, on pumping units used where flammable or
fire, burn, extreme cold or chemical explosive vapors could form, all electric motors used as
attack. power sources must be of explosion proof construction
and all electrical components and wiring must meet the
current National Electrical Code for explosive atmosp-
Never operate a pump which is pumping hydrocarbons heres.
or other flammable, hot, cold, or corrosive fluids when
These precautions must be taken to avoid possible per-
any part of the pump, suction system or discharge sys-
sonal injury, death and/or equipment damage from ex-
tem is leaking. Stop the pump immediately if any leak-
plosion, fire or burns.
age, other than a few drops per minute of packing
weepage, is observed. Keep all flame, sparks, or hot HIGH PRESSURE LIQUID JETTING, BLASTING
objects away from any part of the pump, suction sys- AND CLEANING
tem, or discharge system. Shield the pump, suction
system and discharge system to prevent any flam-
mable, hot, cold or corrosive fluid leakage from dripping
or spraying on any components, flame, sparks, hot ob-
jects or people. Inspect the plungers, packing, gaskets
and seals for fluid leakage frequently and replace all Extreme caution must be exercised if
worn or leaking parts. any type of wand, gun, nozzle or any
Selection of the proper gaskets, seals and stuffing box other pressure and flow directing de-
packing is even more critical when flammable, hot, cold vice is attached to the pump dis-
or corrosive fluids are being pumped than when other, charge system for use in jetting,
inherently less dangerous fluids are used. Contact a blasting, cleaning, etc. This type of
Gardner Denver Machinery service representative for
equipment must be used with utmost
assistance in selecting the proper gaskets, seals and
packing before beginning operation. care by trained, experienced opera-
tors. High pressure fluid streams can
Since some packing weepage into the cradle area is in- either by direct contact or by propel-
evitable, the drain at the bottom of the cradle must be
connected to a drain line which conducts the fluid leak- ling loose objects, cause serious per-
age to a collection container located in a protected sonal injury or death to the operators
area. The entire drain system and container must be and/or other persons.
constructed of materials resistant to attack from the
pumped fluid or from explosion or fire of the pumped
fluid. Heavy duty cradle covers must be securely Pressure or flow directing devices often receive pres-
fastened in the proper position on the pump at all surized flow through flexible hoses, which can burst if

3–1–614 Page 5
they are kinked, cut, abraded or are otherwise worn, and the electrical power to these devices must be shut
damaged or pressured above their rated capacity. Pro- off to avoid electrical shocks from fluid contact. The
tect the hose and connections from damage by people, work area should be clearly marked and roped off to
objects and vehicles. A broken, cut or otherwise burst keep unauthorized people and vehicles from entering.
hose can release pressurized fluid which may cause Remove all loose parts, tools and equipment from the
personal injury, death and/or equipment damage. work area before beginning operation.

High pressure fluid from hand held or hand directed All pressure containing devices including wands,
pressure and flow directing devices may overpower an nozzles, guns, hoses, connections, etc., should be reg-
operator’s ability to control or direct the device, which ularly checked for condition. These components
could lead to personal injury, death and/or equipment should all be tagged with their tested pressure capabili-
damage. The operator must brace against the back- ties together with the date testing was performed. Al-
ward thrust of a hand held device. In addition, a safety ways be aware of the pressure level in the system
harness or safety net must be used when working in an and never connect any equipment to the system
area where the operator could be injured in a fall. Stand which has a rated or tested pressure capability be-
to the side of any tubing or container being sprayed to low the system operating pressure. The equipment
avoid back spray and never operate a hand held device must be shut down and the system pressure released
above shoulder level. before changing or disconnecting wands, nozzles,
guns, hoses, connections or any other pressurized
Never direct the pressurized fluid stream at yourself or system components.
any other person, control valves, the pump, pump
All pressure containing devices including wands,
drive, suction or discharge systems. The pressurized
nozzles, guns, connections, etc., plus all automatic
stream can cause serious personal injury or death and
shut–off, pressure and control equipment should be
can also change valve or control settings which could
treated with care. Protect them from damage by
dangerously increase the delivery pressure to the pres-
people, objects and vehicles. Never lay them in dirt,
sure and flow directing device.
mud, ice or other loose material which could plug the
When operating a pressure and flow directing device, fluid opening or interfere with their operation. Never
use only equipment which automatically shuts off flow use the wand, nozzle, gun, etc. to pry loose material off
when an operator releases hand or foot pressure on the items being cleaned.
pressurized flow trigger control to prevent injury if the Before starting operation in a cold environment, check
operator is overpowered or becomes disabled. to make sure there is no ice in the fluid system and re-
Check to insure this automatic shut–off equipment is peat this inspection each time before operation is re-
operating properly before every use and never circum- started.
vent the automatic shut–off for any reason or by any Before purchasing wands, nozzles, guns, connections,
means when operating the equipment. and hose, etc., manufacturers of these components
should be contacted for detailed information on the de-
When operating any type of high pressure liquid jetting,
sign and safety features incorporated in their products.
blasting or cleaning devices the operators must always
After careful study of various manufacturers products,
wear protective clothing including, but not limited to, a
we recommend that only those wands, nozzles, guns,
hard hat with full face visor, heavy duty rain coat and connections and hose, etc., be considered for pur-
pants, boots with nonskid sole and safety toe, rubber chase that you judge to offer the highest quality of de-
gloves with rough grip surface and ear noise protection. sign, construction and safety, since these components
Full operator attention and alertness are required when are among the most critical to the safe operation of high
operating this equipment to avoid personal injury, death pressure liquid jetting, blasting and cleaning equip-
and/or equipment damage. The operators should take ment.
frequent rest breaks and cease operations when they After you have selected and purchased these compo-
become tired or distracted. nents, follow the manufacturer’s instructions complete-
ly in their use.
Before the equipment is started, the work area must be
inspected and properly prepared to avoid personal inju- In summary, high pressure jetting, blasting and
ry, death and/or damage to equipment. Make sure the cleaning are inherently dangerous, as the pressur-
work area is checked for hazardous fumes, has ade- es and flow rates needed to remove scale, clean,
quate ventilation for engine exhaust and sufficient etc. are sufficient to cause personal injury, death
drainage for released fluid. Check the work area for and/or equipment damage resulting from, but not
electrical equipment, connections, outlets, fixtures, or limited to, any of the conditions described in the
lines. If any are present they must be made water tight above Danger Notices.

3–1–614 Page 6
SECTION 2
OPERATING AND MAINTENANCE INSTRUCTIONS

the next larger size pipe or hose should be used. The

suction line should have a very slight, constant upward
grade toward the pump to insure air pockets do not form
in the line. The suction line must also be air–tight. Both
Always wear safety shoes and air pockets and air leaking into the line will reduce the
goggles when operating and perform- pump volumetric efficiency and produce shock loading
ing maintenance or repair on a pump inside the pump. Any bends in the suction line should
or pump package unit to help prevent be long radius sweeps. All piping must be supported in-
personal injury to eyes and toes from dependently of the pump to insure that no strain is im-
posed on the pump by misalignment, vibration or im-
pressurized fluids and falling or flying properly fitted pipe. Any suction line shutoff valve(s)
objects. must be full opening to avoid choking the pump.

INSTALLATION

LOCATION – The pump should be located as close to

the fluid supply as possible. A short, straight suction The suction line strainer, if used,
line will provide the best pump performance and re- must be cleaned frequently. A
duces the possibility of cavitation. clogged or partially clogged strainer
can cause severe pump cavitation,
The pump must be driven in the direction indicated by poor expendable part life and poten-
arrows on the frame, that is, the crankshaft must rotate tially serious pump damage.
over center toward the crosshead oil trough. Rotation
in this direction is necessary to assure adequate cross-
head and crosshead bushing lubrication.

Adequate space should be provided around the pump Many potential pumping problems can be avoided by
for ease of inspection and service. The pump must be reviewing the proposed pump layout and suction condi-
leveled and checked for gaps under all frame feet. Shim tions with Gardner Denver Machinery Inc. Marketing
any gaps to prevent frame damage when the feet are before a pump is purchased.
securely fastened to the foundation or base. Pump
frame damage may also occur on truck mounted units PRESSURE RELIEF VALVE – The pump must be pro-
due to truck frame flexing, unless a stiff base or isolators tected from excessive discharge pressure by a pres-
are used between the pump and truck frames. sure relief valve. This valve must be properly sized to
handle the full flow of the pump and must be installed
The maximum allowable temperature of the pumped as close to the pump discharge connection as possible.
fluid is 200_F (93_C). Any pump application over this
temperature, or with a suction pressure over 50 psi,
must be approved in writing by Gardner Denver Ma-
chinery Inc. Marketing.

Never install a shutoff valve in the line

SUCTION SYSTEM – Suction system conditions are between the pressure relief valve and
critical to proper pump performance and durability. Ade- the pump cylinder, as pumping
quate suction pressure, as shown on the NPSHR against a closed valve could produce
graph, page 27, must be provided at the pump suction pressures sufficient to cause proper-
connection.
ty damage and/or serious personal in-
The suction pipe or hose should be the full size of the jury or death.
pump inlet opening. If the suction line is relatively long,

3–1–614 Page 7
 Improper use or maintenance of pres- The pump must be primed at start–up
sure relief valves can cause exces- to prevent damage to packing and
sive pressure which may result in plungers.
property damage and/or serious per-
sonal injury or death.
The pump should be started slowly, but should never be
run below the minimum speed shown in the back of the
manual. The pump should not be started under load and
The relief valve should be set to operate at approxi- should be operated for several hours with practically no
mately 1.1 times the discharge pressure, but MUST discharge pressure. A start–up bypass line should be
NOT exceed equipment tolerances and ratings. used whenever the pump is started, to gradually bring
the pump up to working speed and pressure. After the
pump has run a short time, check the oil level as it may
Check the valve for proper functioning at lease once a be necessary to add a small amount of oil to compen-
month. sate for the oil adhering to the crankcase walls and mov-
ing parts.
STARTING A NEW PUMP – The power end inspection
plate should be removed and the crankcase examined. The oil level in the TQ model pumps is checked when
Clean out any dirt or moisture that may have accumu- the pump is not running. The proper fill for these pumps
lated during shipping or storage. Check all pump fasten- occurs when the oil is level with the top of the elbow
ers for proper tightness. threaded into the lower portion of the frame end plate.

The oil level on TA, TD, TF and QB model pumps should

be checked with the pump running. The running level on
these pumps should be between the middle and top of
the sight glass in the oil level indicator, located on the
side of the pump frame. Add oil to all pumps through the
Pumps are shipped from the factory threaded opening where the breather is mounted. The
without oil in the crankcase. breather is threaded into the top of the frame, or into an
elbow attached to the frame end plate. The pump may
then be brought up to working speed and pressure.
Check for overheating and listen for abnormal noise. In-
Add oil through the opening where the breather is lo- spect all joints in the suction line to be sure there are not
cated. The breather is threaded either into the top of the air or fluid leaks. Check for excessive vibration caused
frame, or into an elbow attached to the upper part of the by improper suction conditions. Be sure the stuffing box
frame end plate. Fill the crankcase with the quantity of packings are properly lubricated per the directions giv-
oil shown on the nameplate attached to the pump en in the packing lubricator section.
frame. Refer to the lubrication data plate and LUBRICA-
TION section, below, for the proper oil specification. LUBRICATION – The crankshaft, crossheads, con-
necting rods and main bearings are lubricated by oil in
the crankcase.

The cradle cover, all guards and in-

spection plates must be securely fas- Use only extreme pressure, API GL–5
tened in proper position before the gear oil, having the required additives
pump is started and must not be re- and viscosity, in the crankcase. The
moved at any time when the pump is use of motor oils in the crankcase
in operation, to avoid personal injury does not provide acceptable lubrica-
and/or death from moving parts. tion and voids the warranty.

3–1–614 Page 8
The selected API GL–5 oil must have antiwear, anti- crankcase is kept closed, the normal change interval is
foaming, noncorrosive and rust inhibiting additives. A 1000 hours. However, the oil must be changed any time
list of recommended grades vs. temperatures is located water or other contamination is found in the oil.
on page 24, and on the pump lubrication data plate.
On pumps equipped with a magnetic drain plug, check
The list is based on premium quality oils having viscos- the magnet for metal chips whenever the oil is drained.
ity values that do not exceed 7000 SSU at the minimum If chips are found, remove the frame end plate and the
start–up oil temperatures listed and viscosity values be- plugs over the crosshead oil reservoir. Clean and flush
tween 1500 SSU and 200 SSU for the crankcase oil the crankcase through these openings before adding a
temperatures listed. Oils with viscosity values signifi- fresh oil fill.
cantly different from these values, at the temperatures
listed, may be too thick at low temperatures to flow into Some operating conditions and/or oil brands produce
close bearing clearances, or may be too thin at high excessive oil foaming, even when the specified GL–5
temperatures to carry the required loads. In either case oils containing antifoaming additives are used. Oil
pump damage could occur. foaming can cause pump damage, as oil bubbles will
not lubricate moving parts properly. If significant oil
If a 7000 SSU maximum viscosity at start–up cannot be
foaming occurs, contact Gardner Denver Machinery
assured, a crankcase heater is required. Also if crank-
Inc. Marketing or Service for the current factory recom-
case oil temperatures exceed 200_F (93_C), an oil heat
mended defoamant to be added to the lubricating oil.
exchanger with a circulating pump is required to prevent
When it is not possible to contact Gardner Denver, a
seal damage and oil break down.
small amount of kerosene added to the oil will usually
For outdoor operation, multiviscosity oils are preferred reduce foaming. One half of a fluid ounce of kerosene
to provide acceptable lubrication over wide temperature added to each gallon of oil should be sufficient to control
ranges. However, when multiviscosity oils are not avail- foaming. The use of larger amounts of kerosene per
able, straight weight oils should be acceptable, if care gallon of oil will reduce the oil viscosity, which could re-
is taken to stay within the listed temperature ranges. sult in rapid pump wear and failure.
Straight weight oils are also ideal in pumps used in-
doors, when ambient temperatures are controlled. If the pump has been stored or shut down for an ex-
tended period, the crankcase should be drained and
The oil level in the pump should be checked frequently. filled with new oil before start–up.
Add oil through the breather opening. The breather can
be removed by rotating it counter clockwise. Keep the
breather tightly in place while the pump is operating to OPERATION – The pump should always be started
prevent moisture and dirt from entering the crankcase. slowly, with little or no discharge pressure, to give the
On pumps equipped with a replaceable filter element oil time to warm–up and flow to all the bearing surfaces.
type breather, clean the element frequently and replace This warm–up is especially important during cold
the element every six months. When operating in very weather operation.
dusty or dirty conditions, more frequent replacement
may be necessary.

The pump must never be operated in

reverse direction, at pressures or
The oil should be checked for con- speeds above the maximum values
tamination whenever pumped fluid shown on the nameplate, or at speeds
sprays or splashes against an oil stop below the minimum value shown in
head. This is especially critical when the back of the manual, without writ-
the fluid contains salts or solids, as ten permission of Gardner Denver
these contaminants can plug lubri- Machinery Inc. Marketing.
cating passages and cause rapid
power end failure. Failure to observe this warning could
result in severe pump damage due to
overloading and/or lack of adequate
The time between oil changes depends on the pump lubrication.
location and operating conditions. Ordinarily, if the

3–1–614 Page 9
FLUID END CORROSIVE ATTACK – Some aluminum lyzed and/or one or more sacrificial anodes should be
bronze fluid cylinders and components (especially placed in the suction fluid stream. If the water analysis
valve decks and seats) experience corrosive attack shows corrosive chemicals are present, or on frequent
from chemicals in the water being pumped. To avoid inspection the anode is observed to be eaten away, the
damage to pump components, water containing corro- fluid should be treated.
sive chemicals should be treated to neutralize corrosive
properties before it is pumped. Anodes, mounted on threaded plugs, are available from
Gardner Denver Machinery Inc. to replace one or more
To determine if corrosive chemicals are present in of the drain plugs located in the bottom of aluminum
pumped water, a sample should be chemically ana- bronze suction manifolds.

3–1–614 Page 10
 SUGGESTED PERIODIC MAINTENANCE SCHEDULE

After 2–Hour

Every 3 to 4
Start–up

Monthly

Months
Weekly
Daily
Item Maintenance / Inspection

POWER END

1 Lubricator operation X X
2 Lubricator sheave alignment and belt tension X X
3 Pump drive belt slippage X X
4 Pump drive sheave alignment and belt tension X X
5 Plunger coupling condition X X
6 Plunger coupling fastener torque X X
7 Sheave fastener torque X X
8 Prime mover mounting fastener torque X X
9 Pump mounting fastener torque X X
10 Crankcase oil level and quality X X
11 Crankcase oil change every 1000 operating hours
(or sooner if contaminated)
12 Any oil leaks X X
13 Breather/filter element condition X
14 Extension rod to crosshead torque X X
15 Connecting rod nut torque X X
16 Crankshaft bearing housing bolt torque X X
17 End play or preload crankshaft bearing X X
18 Baffle disc X X
19 Lubricator oil tank level X
20 All exterior locking devices X X

FLUID END

1 Packing Leakage X X
2 Stuffing box condition (after packing replacement) X X X X
3 Any liquid leakage X
4 Fluid cylinder to frame nut torque X X
5 Suction/discharge manifold stud nut torques X X
6 Stuffing box nut torque X X
7 Companion flange nut torque X X
8 Valve assembly condition X
9 Pump discharge relief valve setting and condition X
10 Packing gland tightness
11 Plunger condition X X
12 Suction/discharge valve cover fastener torque X X

3–1–614 Page 11
 D72650A

FIGURE 1 – REAR SECTIONAL VIEW OF TRIPLEX POWER END SHOWING CRANKSHAFT

E77126

FIGURE 2 – TOP SECTIONAL VIEW OF QUINTUPLEX POWER END SHOWING CRANKSHAFT

3–1–614 Page 12
3–1–614
Page 13

E77125

FIGURE 3 – SECTIONAL VIEW OF TRIPLEX AND QUINTUPLEX PLUNGER PUMPS

SECTION 3
SERVICE INSTRUCTIONS

FLUID CYLINDERS – One piece cast fluid cylinders Several different valve options are offered for the pump
are made for low and medium pressure service in alumi- models covered by this manual. Consult Gardner Den-
num bronze for water and some other corrosive fluids ver Machinery Inc. Marketing Department or your near-
and for some models in nodular iron for noncorrosive est salesman if you need help in deciding which valves
fluids. Cylinder suction and discharge openings are to use.
equipped with either flanges and studs or internal
threads. All valve covers are secured with studs and DISC VALVES – This style of valve, made of either alu-
nuts. Valve seats are held in by taper fit. minum bronze or stainless steel, is used as standard
equipment in low and medium pressure tapered seat
Block fluid cylinders are made for high pressure and/or deck fluid cylinders. Monel valves are also available for
corrosive fluids in steel, stainless steel or aluminum fluids that attack aluminum bronze and stainless steel.
bronze materials. These fluid cylinders are made with Delrin (or Celcon) discs are recommended for water
removable bolt–on suction manifolds and, in some and most clean fluids up to 160_F (71_C). Titanium
cases, bolt–on discharge manifolds. Cylinder suction discs are specified for fluids with higher temperatures,
and discharge openings are equipped with flanges and trace amounts of abrasives and with fluids that attack
studs or bolt–on replaceable, internal threaded blocks. Delrin (but not titanium) discs.
All valve covers are secured with studs and nuts. Valve
seats are held in by either taper fit or are clamped be- The valve plate, springs and retainer are secured by a
tween the cylinder and the manifolds. fastener that passes through these parts and threads
into the seat. These parts can all be lifted out and in-
Torques required to properly tighten fluid end fasteners spected by removing the fastener. The seat should be
are listed by model on pages 37 thru 63. These fasten- removed, using the properly sized puller assembly
ers should be checked frequently for tightness. A loose shown in the pump parts list manual. Puller kits can be
or improperly torqued fastener may break under pulsat- purchased as optional equipment from Gardner Denver
ing fluid end loads. Machinery Inc.

TAPERED SEAT VALVES – This type of valve is re- Note that two different types of puller heads are used to
tained in the cylinder by the locking action of the match- remove disc style valve seats. For larger seats, a
ing valve seat and deck tapers. slotted finger design head slips down through the seat
openings and is then rotated to engage the seat ribs.
The valves should be examined regularly for excessive For smaller seats, the seat openings are not large
wear and for coating or particle adhesion that may pre- enough to use this design puller head. The smaller seat
vent proper valve opening and closing. A valve that is puller heads have a center threaded bolt or stud which
not sealing, opening or closing properly, or a seat that screws into the threaded center hole in the seat.
is improperly seated in the deck, can fail quickly by ero-
sion of the valve, seat or deck.

Access to the discharge valves is gained by removing

the valve covers on top of the cylinder. The valve covers
are held in place by studs and nuts. The retainers or
Wear eye protection when removing
cages, springs and discs or valves must be removed the valve seat as metal chips could be
before the seats can be inspected or pulled. The suction dislodged from the valve seat or valve
valves can be examined after the discharge valve seats puller and fly up into your face.
have been removed with a valve seat puller. The suc-
tion valve seats are also removed with a valve seat pull-
er.
When preparing to remove a valve seat, tightly as-
The outside diameters of suction valve seats on all cyl- semble the proper finger or threaded design puller head
inders without suction valve covers are smaller than on the smaller thread end of the puller rod. Insert the
those on the discharge valves, to enable the suction puller head and rod into the valve cover opening on the
valves to be installed and removed through the dis- top of the cylinder and either engage the puller fingers
charge valve decks. However, where the suction valve in the seat or tightly thread the head into the seat. Slip
covers are used, the suction and discharge valves may the puller plate onto the puller rod using the center hole
use the same size seats. in the plate. Lower and rotate the plate until two studs

3–1–614 Page 14
on opposite sides of the valve cover opening line up with Additional hits may jar the seat loose and could damage
two holes in the puller plate. Continue lowering the plate the seat. Check the seat top surface to see that it has
over the studs until the plate rests on top of the cylinder. not been damaged after the seat has been installed.
Place the stepped washer (stepped side up) over the
puller rod and drop it down on the plate. Put the flat After all suction valve seats have been installed, place
washer and then puller nut on the puller rod. Push the the valve plates, springs and retainers in place, then se-
puller wedge between the stepped and flat washers cure with the retainer bolt. Carefully position the valve
with the two wedge legs straddling the puller rod and plate and retainer, so as not to pinch the plate closed or
with the outer edge of one leg against the step on the damage the guide while tightening the fastener. Torque
stepped washer. the retainer bolt to the value shown in the table at the
back of the manual. If the seat comes loose from the ta-
Continue pushing the wedge between the washers until per when the disc, spring and fastener are being
the wedge leg tips reach the opposite edges of the two installed, the valve must be disassembled before strik-
washers. Holding the wedge in this position, firmly tight- ing the seat again.
en the puller nut with a properly sized wrench. The seat
can then be pulled by striking the stem end of the wedge
with a heavy hammer. This type of puller uses a com-
bination of pull and impact to disengage the seat from
the cylinder deck taper. It is possible to lock a valve closed by
Do not use a hydraulic jack type seat puller with a disc
either mispositioning the retainer
valve seat that has a small threaded hole in the center stem on top of the valve plate when
used for both the retainer screw and seat pulling. The the retainer bolt is tightened, or by
very strong, steady pull produced by a hydraulic puller overtightening the retainer bolt and
is more likely to break the puller fastener than is the expanding the retainer stem until it
combination pull and impact the wedge puller provides.
contacts the disc bore.
A new valve as taken from the carton should be cleaned
thoroughly with solvent and wiped dry with a clean cloth.
After all suction valves are in place, the discharge
Check tapered surface to be sure it has not been acci-
valves are installed in the same manner. Install the
dentally nicked or dented in handling. The valve assem-
valve covers and gaskets. Tighten the cover stud nuts
bly should be disassembled by removing the single fas-
to the torque listed at the back of the manual.
tener; be careful not to lose the small nylon thread lock
plug. WING GUIDED AND SEVERE DUTY VALVES –
These valves are used in high pressure, tapered seat
deck cylinders where pressures are too high for disc
style valves. They are also used in low and medium
pressure cylinders, where disc valves cannot tolerate
fluids with high temperatures, abrasives or chemicals
Never attempt to install the valves as that attack the discs. Some of the wing guided and se-
vere duty valves are offered with urethane insert op-
an assembly. The valve could be tions to handle high abrasive concentrations. However,
damaged when a block and hammer the inserts will not hold up in fluids with temperatures
are used to strike the retainer to set above 160_F (71_C) or in fluids that attack urethane.
the seat. These valves are retained by a cage that screws onto
the seat. A valve cage removal tool can be purchased
from Gardner Denver Machinery Inc. Refer to the Parts
List for the part number.
Wipe the taper surface of the seat and pump port taper
with a clean cloth. Lower the seat into port taper and The wing guided valves can be removed with one of two
then lift slightly and drop. If the seat drops straight, it will types of puller heads, threaded on the puller rod. The
seize on the taper sufficiently that it cannot be pulled up first type head uses the retainer attaching threads on
by hand. It is necessary to strike the seat once to assure the top of the valve seat. Since only a few threads are
a perfect seat. This may be done with a short section of required (and provided) to hold the cage to the seat,
hard wood and a four–pound (1.8 kilogram) hammer. these threads can be easily damaged by a puller head
The end of the wood block placed against the valve seat if the seat is hard to pull. Therefore, a hydraulic jack seat
should be large enough to cover the outer sealing ring. puller is not recommended for use with this style puller
One sharp blow should be sufficient for proper seating. head.

3–1–614 Page 15
The second type of puller head uses a cam arrange- made to install the seat. Again use only one sharp blow
ment to pass through the seat opening and engage one on the block or driver after dropping the seat into the ta-
side of the seat bottom. This type head is preferred per. Excessive pounding could loosen or damage the
since it is less likely to damage the seat during the pull- seat.
ing procedure. When using either type of puller head,
follow the valve pulling procedure outlined in the disc Some pump models use flat valve covers with gaskets,
valve section of this manual. The second type of puller while others use round valve covers, O–rings and re-
head can be used with a hydraulic jack type puller. taining plates. Inspect the valve cover and cylinder
sealing surfaces to insure they are in good condition
and install a new gasket or O–ring. Install either the flat
cover, or the round cover, retainer plate and hardened
steel washers, and tighten the stud nuts to the torque
listed in the back of the manual.
If a seat puller powered by a hydraulic CLAMPED SEAT VALVES – This type of valve is
jack is used, be certain to chain or tie clamped between the fluid cylinder and either the suc-
the jack down as it will jump violently tion or discharge manifold. The suction (front) and dis-
when the valve seat lets go. charge (top) manifolds are held on the fluid cylinder with
studs and nuts. These cylinders are designed for ease
of valve replacement in high pressure services. Ta-
pered valve seats are often difficult to remove from high
The severe duty, tapered seat valves can be removed pressure cylinders.
with one of two types of puller heads. The first type head
When replacing suction valves, remove the manifold
has threads on the outside diameter that match the
stud nuts and slide the manifold outward on the studs
threads cut into the inside diameter of the seat. The se-
until further movement is prevented by the built–in man-
cond type head uses the same type cam arrangement
ifold retaining screws.
described in the wing guided section above. When us-
ing either type of puller head, follow the valve pulling
procedure described in the disc valve section of this
manual. A hydraulic jack type puller can be used with
either of these heads.
Do not remove the expansion plugs
Before installing a valve, make sure the seats and deck
tapers are clean and dry. Inspect both seats and deck
and retaining screws when servicing
tapers to insure they are not scratched, nicked or other- suction valves. These parts stop the
wise damaged. Replace any seat found damaged and suction manifold from sliding off the
have any damaged deck tapers remachined. Do not ends of the studs and falling, which
coat the tapers with any kind of lubricant or coating be- could cause equipment damage and/
fore assembly.
or serious personal injury or death.

If flexible suction and discharge lines are not attached

to the pump, the suction and discharge connections
Never attempt to install wing guided must be removed before the manifold can be slid away
valves as assemblies as the valve from the cylinder. After the manifold has been slid out,
cage will be damaged. the valves can be removed, inspected and replaced as
necessary. Before replacing the valves, inspect the
valves, manifold and cylinder surfaces and the valve
Drive the seat into the taper using a four–pound (1.8 gaskets to insure they are not scratched, nicked or
kilogram) hammer striking either a wood block (cover- otherwise damaged. Make sure the cage is tightened
ing the full upper surface of the seat) or one of the facto- on the seat to the torque level listed in the back of the
ry option valve seat drivers that thread onto the various manual. Install the gaskets in the valve grooves and
style valve seats. One sharp blow on the block or the position the valves in the cylinder bores with the cages
rod end of the driver should be sufficient for seating. If in the cylinder. Slide the suction manifold along the
the seat jumps up when it is struck, take it out and in- studs and pilot the suction valve seat into the manifold.
spect both the seat and the deck tapers. They must be Tighten the suction manifold stud nuts to the torque val-
clean, dry and undamaged before a second attempt is ue listed in the back of the manual.

3–1–614 Page 16
If the suction manifold and/or fluid cylinder must be re- various fluid cylinders used on the pumps.
placed, remove the expansion plugs and retainer
screws (socket head capscrews) from the suction man- When servicing a stuffing box, plunger or packing, start
ifold. Support the suction manifold with straps and a by removing the plunger to extension rod coupling.
hoist, so it cannot fall when the manifold is removed. Keep the coupling halves together as sets. Do not inter-
Unscrew the suction manifold stud nuts, slide the suc- mix halves.
tion manifold off the ends of the studs and lower the
manifold to the floor with the straps and hoist. When re-
installing the suction manifold, tighten the retainer
screws to the torque listed in the back of the manual and
drive in new expansion plugs to the same depth in the
bores as the removed plugs were located.
After removing the plunger to cross-
head extension coupling, do not use
The replacement procedure for the discharge valves is a screwdriver or cold chisel to sepa-
similar to that used for the suction valves. However, rate the extension and plunger
since the discharge manifold must be lifted upward on
flanges, as burrs may be formed
the manifold studs, two threaded holes are built into the
manifold to enable it to be lifted with the aid of a hoist. which could cause misalignment on
To replace the valves, remove the discharge manifold reassembly. Instead, rotate the ec-
stud nuts, install two eye bolts in the threaded holes and centric slightly. If the parts do not
lift the manifold with a hoist. separate, carefully slip a pipe wrench
around the plunger neck and use a
pulling and rotating motion to sepa-
rate the plunger from the extension
rod. Use caution to avoid damaging
Use only eye bolts which are in good the plunger wear surface.
condition, have a rated lifting capac-
ity greater than the manifold being
lifted and are installed to the full Continue to rotate the crankshaft to pull the extension
length of their threads into the man- rod away from the plunger as far as it will go. Remove
ifold. Failure to follow this notice the gland nut and the stuffing box stud nuts. Lift the
could allow the manifold to fall, which stuffing box, plunger and packing assembly out through
the cradle opening in the top of the pump frame. Lay the
could cause equipment damage and/ stuffing box assembly on a work bench and slide the
or serious personal injury or death. plunger and packing out of the stuffing box.

When replacing the stuffing box, plunger and packing

assembly, the above procedure is reversed. However,
After the discharge manifold has been lifted up, the dis- first inspect the stuffing box bore for scratches, wear or
charge valves can be removed, inspected and replaced other defects. Clean and check the stuffing box face,
as necessary. Before replacing the valves, inspect the gasket groove and outside diameter that pilots into the
valve assemblies, manifold and cylinder surfaces and frame, to insure they are free of defects, burrs and dirt.
the valve gaskets to insure they are not scratched, Clean out any burrs, dirt and rust in the stuffing box pilot
nicked or otherwise damaged. Make sure the cage is bores in the frame. Install the packing in the box. Place
tightened on the seat to the torque level listed in the a new gasket in the stuffing box groove. The gasket
back of the manual. Install the gaskets in the valve chamfered edge must face out to prevent gasket pinch-
grooves and position the valves in the cylinder bores ing when the stuffing box and cylinder surfaces are
with the seat in the cylinder. Lower the discharge man- pressed together.
ifold onto the valve flanges while taking care the pilots
on the valve flanges fit into the openings in the dis- Place the stuffing box assembly on the stuffing box
charge manifold. Install the discharge manifold stud studs. If the stuffing box does not enter the frame easily,
nuts and tighten them to the torque value listed in the do not hit the box with any type of hammer, as you may
back of the manual. damage the box or dislodge the gasket from the groove.
Instead, remove the box and recheck the frame bore for
STUFFING BOXES – Stuffing boxes made from differ- dirt or rust build–up and the stuffing box pilot for dirt or
ent materials and in several sizes can be matched with damage. Install and torque the stuffing box stud nuts to

3–1–614 Page 17
the value listed in the back of the manual. Alternately NOT USE GREASE. Install the packing and compo-
tighten the nuts diagonally across from each other to in- nents in the stuffing box in the same order as the parts
sure the gasket is drawn up evenly. Install the gland were removed. When using lip style packing, be sure
bushing and gland on the box. the lips of the sealing rings face the pressure (toward
the fluid end). Coat the plunger with oil and slide it into
the packing.
PLUNGERS – Plungers with Colmonoy, ceramic or
tungsten carbide wear surfaces are normally used, de-
pending on the service conditions. However, other ma- Install stuffing box, plunger and packing as an assem-
terials can be supplied for special applications. bly on the fluid cylinder, using the procedure described
in “Stuffing Boxes,” page 17.
Before installing a new plunger, or reinstalling a used
plunger, check for scratches, pits, nicks or a rough fin-
ish on the plunger wear surface. Inspect the mating pi-
lots and ends of both the plunger and extension rod for
burrs and dirt. Check to make sure the extension rod pi-
lot knob is not broken or damaged. A broken knob could This procedure details that the gland
also be lodged in the plunger pilot hole. Replace any should not be threaded on the stuff-
damaged parts. Burrs, other damage, or dirt between ing box before the box is assembled
the plunger and extension rod ends and pilots can mis-
align a plunger and lead to early plunger and packing on the fluid cylinder
failure. This assembly sequence is recom-
mended, since on most pump models
Use only Gardner Denver replacement plungers, as
the gland will interfere with the
many other brands do not have the material quality or
fine surface finish needed to provide long plunger and wrench and/or socket used to tighten
packing life. the stuffing box retaining nuts, partic-
ularly nuts on the bottom side of the
A plunger, packing and stuffing box should be installed box.
in the pump as an assembly (see “Stuffing Boxes,” page
17). After this assembly has been completed, take the
plunger coupling halves that had been kept as a
matched set from the time of disassembly, and install When the nonadjustable packing is used, tighten the
the set using the fastener torque listed at the back of the gland firmly with a 24 inch section of one half inch pipe
manual. If one coupling half has been damaged, do not placed over a lock pin, which has been inserted in a lock
use a new half with a used half. Instead, use a complete pin hole in the gland. When using self adjusting packing,
new coupling set. Tighten the coupling evenly so the tighten the gland nut firmly, after assembling it metal to
gap between halves is the same on both ends. metal with the stuffing box. Do not overtighten the nut,
as the threads or lock pin holes could be damaged.

PLUNGER PACKING – The stuffing boxes are packed

with nonadjustable lip type packing for low pressure,
general service applications. Self adjusting packing in
various lip styles and braided configurations is also of-
fered for higher pressure and/or special service condi- Regardless of the packing used, the
tions. Lubrication is required for all lip style and most gland must be engaged by at least (3)
braided style packings. Packing lubricating oil types
and required flow rates are discussed in “Packing Lubri- threads to hold the pump discharge
cator,” page 19. pressure. An improperly tighten
gland could cause personal injury,
Before installing the packing, clean the stuffing box and death and/or equipment damage.
check the bore for nicks, scratches and wear. A dam- This can occur either through direct
aged box should be replaced to avoid early packing fail- contact with the pressurized flow or
ure. Inspect all metal and/or plastic packing rings, by contact with objects the fluid
spacers and bushings to insure they are clean and free
of nicks and burrs. Always install new packing rings in
stream propels.
complete sets. Coat all packing parts with light oil, DO

3–1–614 Page 18
 covered by this manual are designed to run at low
enough speeds so that crankshaft counterweights are
not required for smooth operation.

Do not attempt to adjust packing All crankshafts covered by this manual are supported
while pump is in operation to avoid by tapered roller outer main bearings. The bearing cups
remain in the bearing end plates when the plates are re-
personal injury or death from moving
moved. Quintuplex pumps also have a straight roller
parts. bearing supporting the center portion of the crankshaft.
The inner race of the center main bearing is held on the
crankshaft with a shrink fit. A retainer ring positioned in
When using the nonadjustable packing, operate the a groove cut in the crankshaft is used as a retention
pump for two (2) or three (3) hours under pressure, stop back–up.
the pump, relieve the pressure and retighten the glands
to prevent packing movement. When removing the crankshaft, start by removing the
plungers or extension rods, plus the oil stop head. Drain
Regardless of the style packing used, keep lock pins in the oil from the crankcase and then remove the drive
place to prevent the glands from backing loose. sheave, the frame end plate, connecting rod nuts and
caps and both main bearing end plates. Make sure the
Several other types of packing may be used in standard rods and caps which were paired in the removed as-
stuffing boxes. Installation procedures for other packing semblies are kept together for proper reassembly.
may vary from the above. Additional information can be
obtained by contacting Gardner Denver Machinery Inc.
Customer Service.

PACKING LUBRICATOR – A force feed plunger pack-

ing lubricator is required for most packings and is avail-
The crankshaft must be supported
able as optional equipment for all models. The lubrica-
tor is mounted on a bracket over the frame and is driven when removing and installing the
by a V–belt drive off the crankshaft extension. Oil is de- crankshaft end plates to avoid dam-
livered to the tapped opening in each stuffing box aging the bearings.
through steel tubing. The lubricator is equipped with a
check valve at each stuffing box connection.
Use rock drill oil for normal conditions and steam cylin-
der oil for high temperature fluids. Select an oil with the End clearance for the outer main bearings is adjusted
proper pour point for the ambient temperature. Some by adding or removing different thicknesses of color
acceptable oils are listed in the chart on page 25. coded gasket shims between the frame and both crank-
shaft end plates. Clearance on the quintuplex pump
Initially set the lubricator to deliver eight (8) to ten (10) center main bearing is not adjustable.
drops of oil per minute to each stuffing box. More flow
may be required for large plungers and/or high speeds, When removing the crankshaft end plates, write down
pressures or pumped fluid temperatures. Less flow may the number and color of end plate gasket shims re-
be needed for small plungers and/or low speeds or moved and the side of the pump they were removed
pressures. Flow can be controlled by backing off the from. When the end plates are reassembled, install the
jamb nut that locks each plunger body in position on the same number and color of shims as were removed from
lubricator and rotating the plunger body. Rotate the the respective sides of the pump. Push the connecting
plunger clockwise to increase flow and counter clock- rods and crossheads toward the fluid end far enough to
wise to decrease flow. Lock the jamb nuts down again clear the crankshaft. The triplex pump crankshafts cov-
after making an adjustment. Increase the flow if the ered by this manual are reversible end–for–end, while
packing starts to heat up. quintuplex crankshafts are not. However, unless the
main tapered roller bearings are replaced, mark the tri-
CRANKSHAFT – The crankshaft has an extension on plex pump crankshaft orientation, so the original ta-
both ends to enable the pump to be driven from either pered roller bearing assemblies are reunited. The ta-
side. A packing lubricator can be driven off the exten- pered roller bearing cups remain in the crankshaft end
sion not used to drive the pump. The crankshaft is plates as the plates are removed from the frame. The
equipped with paddles to throw oil up into the crosshead straight roller bearing outer race on quintuplex pumps
and connecting rod oil reservoirs. The pump models also stays in the frame as the crankshaft is removed.

3–1–614 Page 19
Using a rope sling for support, remove the crankshaft, When installing a bearing cup in a bearing end plate,
bearing inner races and/or cones with rollers, as an as- wipe all parts clean, inspect for damage and if none is
sembly from either side of the pump. If the roller bear- found, drive the cup into the end plate with a rubber
ings are to be replaced, remove the wear sleeves from hammer. To insure proper lubrication, both main bear-
both ends of the crankshaft, as the inner bearing races ing end plates must be installed with their cast–in oil
will not pass over the wear sleeves. Cut the roller cages trough located above the bearing. This positioning will
off, heat the cones and pull them off the shaft ends. The occur when the end plates are assembled on the frame
center main inner race on quintuplex pumps is removed with the word “TOP” (cast on the plate outer surface) in
using the same procedure as is used on the outer bear- the uppermost position.
ings, except the retainer ring is removed before the
cage is cut off. The end clearance for both main bearings is adjusted
by the use of plastic shim gaskets between the frame
and the bearing end plates. Install each bearing end
The roller bearing cups can be removed from the bear-
plate over its crankshaft extension, using the same
ing end plates by laying a heavy bead of weld around
number and color of new shim gaskets you recorded
the inside of the cup, being careful not to run the weld
were found on that side of the pump when the crank-
onto the bearing end plate. When the cup cools, it will
shaft was removed. Thread all the end plate retaining
normally fall out of the end plate. The center main bear-
screws through the plates and into the frame. Torque
ing outer race on quintuplex pumps is removed by un-
the end plate screws evenly to the torque listed in the
screwing the two set screws at the back of the frame,
back of the manual. Using a pry bar placed against a
pushing the bearing retainer lock pins out of the way
crankshaft paddle and pivoted on a side of the frame
and sliding the outer race out of the frame bore.
end plate opening, firmly push the crankshaft to one
side. Place a dial indicator on the end of one crankshaft
The crankshaft journals are ground and polished to in- extension and firmly pry the crankshaft back in the op-
sure long connecting rod bearing life. Large fillet radii posite direction. Note the dial indicator reading and pry
are ground into the crankshaft to provide superior the crankshaft back in the original direction. Read the
strength. The crankshafts in some models are also heat dial indicator again to confirm it has returned to the origi-
treated for additional strength and wear resistance. Be- nal setting. Compare the dial indicator movement,
fore installing a crankshaft, inspect all bearing surfaces, which is the actual main bearing clearance, to the bear-
fillet radii and wear sleeves for nicks, scratches or other ing clearance listed in the back of the manual. Add or
distress. Inspect the main bearing outer and inner races subtract shim gaskets as required to achieve the re-
and/or cups and cones, rollers for wear and damage. quired clearance, if the dial indicator readings do not fall
Replace the crankshaft, main bearings and wear within the required range. Split the shim pack to equal-
sleeves if damage is found. Wipe all parts clean before ize gasket thickness on both sides.
assembly.
After installing the bearing end plates place a new seal
When installing a new roller bearing cone on a crank- wear sleeve on each crankshaft extension. An installa-
shaft extension, start by heating the cone and roller as- tion tool should be used to insure the sleeve is started
sembly to a maximum of 300_F (if the bearing turns blue squarely on the shaft and is not damaged while being
when heated, it has gotten too hot and should not be driven into position. Be sure to locate the new sleeve in
used). While wearing heavy, insulated gloves, pick up the same exact position as the old sleeve. Install new
the cone and position the wide side of the cone toward oil seals in both bearing end plates, using a .010 inch
the crankshaft extension. Quickly slide cone onto the feeler gauge to roll the lip onto the wear sleeve.
extension until the wide side of the cone is firmly posi-
tioned against the extension shoulder before the cone CROSSHEADS AND CONNECTING RODS – The
cools enough to seize on the crankshaft. crossheads and connecting rods are lubricated with oil
thrown into the reservoirs cast in the frame and con-
necting rods. Oil holes in these parts direct oil to the
The inner race on a quintuplex pump center bearing can
crosshead bushings and connecting rod bearings. To
be installed by sliding the race onto the crankshaft
insure an adequate supply of oil is thrown into the reser-
turned diameter until the race contacts the machined
voirs by the crankshaft paddles, the pumps covered by
shoulder and placing the retaining ring in the ring
this manual must not be run below the minimum speeds
groove.
listed by model on pages 35 thru 60.
To install the crankshaft, reverse the crankshaft remov- The crosshead and connecting rod assembly can be re-
al procedure described above. However, before instal- moved through the oil stop head on TDE, TAE, QBX,
ling the crankshaft, make sure the crosshead and con- TDD and TQC pump models. Begin removal by discon-
necting rod assemblies do not first have to be removed necting the plunger coupling and taking out the rubber
and/or installed through the frame end plate opening. splash baffle. Remove the stuffing box, plunger and

3–1–614 Page 20
packing as an assembly, using the procedure listed in Before installing a crosshead, check the crosshead
“Stuffing Boxes,” page 17. TFE, TDE, TAE, QBX, TDD bore in the frame, the crosshead outside diameter, the
and TQC pumps have removable extension rods, which extension rod (if it is integral with the crosshead) and the
thread into their crossheads. These extension rods can bushings for wear (see clearances in the back of the
be removed and installed by positioning a pipe wrench manual), nicks and scratches. Replace any damaged
over the knurled section of the rod to loosen or tighten parts.
it in the crosshead. Early model TFE, TDE and TAE
pumps had set screws in the crossheads that tighten If new bushings are to be installed in the crossheads,
against the threaded extension rods. Threaded rods note the location of the bushing in each bore and care-
with set screws cannot be unscrewed until the oil stop fully press the old bushings out. DO NOT HAMMER the
head covers are removed and the set screws backed– bushings in or out. Take care to protect the surface of
out. Threaded extension rods without set screws can be the crosshead from damage while pressing the bush-
removed and installed while the crossheads remain in ings. Make sure the bushings and bushing bores in the
place. If in doubt as to whether set screws are used, re- crossheads are in good condition. On pump models
move the oil stop head before attempting to unscrew which have diagonal oil grooves cut into the inside di-
the extension rod and check for the presence of a set ameter of the bushings, make sure the grooves are lo-
screw in the crosshead. All other model pumps have in- cated nearest the extension rod end of the crosshead.
tegral crossheads and extension rods. This position is necessary to provide adequate pin/
bushing lubrication. Align the oil hole in the bushing with
After the oil stop heads have been taken out, remove the oil feed hole in the crosshead and press the new
the frame end plate and the connecting rod bolt nuts bushing into the crosshead bore, to the same location
and cap. Be sure the original rod and cap pairs are iden- you noted the old bushing had been installed. Check to
tified, so they stay together for reinstallation. The rods insure this positioning locates the bushing far enough
and caps are machined together in matching assem- into the crosshead to prevent the bushing outside
blies at the factory. Identical numbers are normally edges from rubbing on the crosshead bore in the frame,
stamped into adjacent edges of a rod and cap near the but not so far into the bore as to bind on the connecting
split line. Different numbers are used for different rod/ rod. Also check to insure the oil holes in the bushings
cap pairs. Proper matching will occur when identical line up with the oil feed holes in the crosshead. If the oil
stamped rod and cap numbers are located on the same holes are badly aligned after installation, press the
edge of the rod/cap assembly. bushings out and reinstall them. If there is any misalign-
ment of the bushing and crosshead holes, run a drill
sized to the full hole diameter down the crosshead oil
If the rod/cap stamped numbers are not visible, use a hole and just through the bushing wall. This will provide
marker to identify the rod/cap pairs as you disassemble full oil flow to the bushings. Hone the bushings to a 5 to
them. After the connecting rod caps have been re- 30 microfinish. See pages 35 thru 61.
moved, slide the crosshead and connecting rod assem-
blies out through the oil stop head openings.
Before installing a crosshead pin in a connecting rod, in-
spect the pin and rod bore for nicks, scratches and
On the TFE, TDD, TQW, TQB and TAC pump models, wear. Measure the pin and the rod small end bore vs.
the crosshead and connecting rod assembly must be the acceptable sizes listed in the back of the manual.
removed through the frame end plate opening. Follow Replace any worn or damaged parts. Make sure the
the same disassembly procedures as described above connecting rod and cap oil reservoirs/holes and the
for the pumps where the crosshead is removed through crosshead oil grooves/holes are assembled so they will
the oil stop head. However, after the connecting rod all face upward when installed in the pump. All pins,
caps are removed, take out the crankshaft, following whether clamped or pressed–in, must be centered in
the procedure described in “Crankshaft,” page 19. Then the crosshead and connecting rod assembly, to insure
slide the crosshead and connecting rod assembly out the two bushings in the crosshead are evenly loaded.
through the frame end plate. On the pump models with a crosshead pin clamp screw,
refer to the torque specification in the back of the manu-
The crosshead pin is held in the connecting rod by a al to insure the screw is properly tightened. On models
clamp screw on the TFE, TDE and TAE models. This with pressed–in pins, coat the pin with oil before press-
screw must be removed before the crosshead and con- ing it in.
necting rod assembly can be separated. The crosshead
pin is pressed into the connecting rod on all other pump Crankpin bearings are steel backed, babbitt lined, pre-
models covered by this manual. Remove and reinstall cision type. The bearing halves can be easily removed
all pressed–in pins with a press. DO NOT HAMMER a from the connecting rod by rotating them out, after the
pin in or out. connecting rod cap has been removed.

3–1–614 Page 21
Before installing the connecting rods and new bearings eter. The oil will lubricate the crosshead and bushings
in the pump, check the new bearings to insure they are at initial start–up, before the crosshead oil reservoir fills.
not nicked or scratched. Also check the connecting rod/
cap bores for nicks, scratches and wear. Replace any
worn or damaged parts.

Pair the identically numbered rods and caps and as-

semble them without the bearings, using the torque val- All oil holes, which are drilled in the
ue listed by model for the rod bolt nuts on pages 37 thru connecting rod and cap oil reservoirs
63. and in the crosshead oil grooves,
must be facing up to provide ade-
Measure the rod/cap bores and the crankpin journal di- quate lubrication.
ameters and compare these readings vs. the accept-
able dimensions listed in the back of the manual. Re-
place any parts that do not fall within the acceptable size
ranges. Install the connecting rods and crossheads as assem-
blies, either through the oil stop head openings or the
Disassemble the rods and caps that have acceptable frame end plate opening, depending on the pump mod-
bore sizes and carefully wipe the bores to insure no dirt el. Be sure to once again match each cap with the cor-
or oil is left on these surfaces. Wipe the bearing insert rect connecting rod.
backs also. Trapped dirt between the bearings and
bores will cause a high spot and rapid bearing wear. Before installing the nuts on the connecting rod cap
Trapped oil could prevent full bearing to bore contact bolts, reach in and feel to make sure the flat on the bolt
and cause the bearing to overheat. Be sure the project- head is seated against the flat relief on the connecting
ing tab on each bearing fits into the corresponding rod. This must be done to prevent the bolt from riding
groove in the rod and cap. Both inserts, comprising a full up the side of the rod. Finally, install the nuts and torque
bearing, are identical. them to the value listed on pages 37 thru 63.

The oil stop heads are attached to the pump frame with
either screws or T–bolts. The T–bolts turn against cast–
in stops on the inside of the oil stop heads and catch the
inside lip of the frame opening. When reinstalling an oil
The oil holes in the bearing halves stop head, check both the gasket and extension rod
must line up completely with the oil seals for wear or damage. Replace any gaskets or
holes drilled in the connecting rod seals that are not in good condition. Also, replace these
parts at any time they are found to be leaking.
and cap to provide adequate bearing
lubrication.
Before installing a threaded extension rod, check it for
wear, scratches or other damage. Replace any rod that
is not in good condition. Apply a coating of GL–5 oil to
the rod, regardless of whether it threads into, or is inte-
Just before assembling the connecting rod and cap, gral with a crosshead, before the oil stop head packing
snap the bearing halves into their respective bores. Ap- is slipped over the rod. Tighten a threaded rod to the
ply several drops of oil to each half and spread it over torque specified at the back of the manual, using a pipe
the bearing surface with a clean finger. This oil will lubri- wrench positioned over the knurled section of the rod.
cate the bearings at initial start–up, before the connect-
ing rod and cap splash oil reservoirs fill.
Slip a rubber baffle over the end of the extension rod
and position it next to the plunger coupling groove, be-
Just before installation in the pump, lay the crosshead fore installing the plunger coupling. Check to insure that
and connecting rod assembly on a work bench with the the baffle fits tightly on the extension rod. Discard any
crosshead oil holes facing up. Fill the crosshead oil used baffle that is damaged or has become too flexible
holes with GL–5 oil. While holding the crosshead, move to maintain its shape while the pump is operating. The
the connecting rod up and down and side to side to dis- baffle is designed to help prevent pumped fluid, which
tribute the oil over the crosshead bushings. Smear a may spray or leak past worn plunger packing, from en-
quantity of the same oil on the crosshead outside diam- tering the crankcase through the oil stop head packing.

3–1–614 Page 22
 the coupling fasteners frequently for proper torque.

Failure to properly install and main-

tain the baffles voids the warranty, as
the crankcase can be damaged by Failure to properly install and main-
pumped fluid entry. tain the plunger couplings can lead to
serious pump damage caused by
plunger misalignment and hammer-
ing.
Inspect the plunger coupling and fasteners. Replace
any of these parts found to be worn or damaged. Tight-
en the plunger coupling fasteners to the torque listed at
the back of the manual. Take care to keep the gap be- Make sure the drain in the cradle and any piping con-
tween the coupling halves as even as possible on both nected to the drain is not blocked. If pumped fluid es-
ends. Replace both coupling halves with a new set if the caping past worn packing builds up in the cradle, it may
halves come together and do not have a gap when tight- enter and damage the power end by splashing against
ened. Do not shim the old parts to achieve a gap. Check the oil stop head packing.

3–1–614 Page 23
 CRANKCASE OIL REQUIREMENTS

Crankcase
API–GL5 Ambient Operating Oil Minimum Startup
Oil Grade Temperature Temperature * Oil Temperature

75W–90 –20_ F to 60_ F 60_ F to 140_ F 20_ F

(–29_ C to 16_ C) (16_ C to 60_ C) (–7_ C)

80W–140 10_ F to 100_ F 90_ F to 180_ F 50_ F

(–12_ C to 38_ C) (32_ C to 82_ C) (10_ C)

80 –10_ F to 45_ F 70_ F to 125_ F 30_ F

(–23_ C to 7_ C) (21_ C to 52_ C) (–1_ C)

90 20 F to 80_ F 100_ F to 160_ F 60_ F

(–7_ C to 27_ C) (38_ C to 71_ C) (16_ C)

140 50 F to 115_ F 130_ F to 195_ F 80_ F

(10_ C to 46_ C) (54_ C to 90_ C) (27_ C)

* An 80_ F (27_ C) crankcase oil temperature rise over ambient air temperature is typical for the
pumps covered by this manual when operating at or near rated horsepower.

Oil viscosity must not exceed 7000 SSU at start–up and must be between 1500 SSU and 200 SSU
while operating, regardless of the oil temperature or grade used. A crankcase heater and/or an oil heat
exchanger may be needed to meet these requirements.

Failure to follow these lubrication requirements will void the warranty.

3–1–614 Page 24
 PLUNGER PACKING
LUBRICATION RECOMMENDATION CHART
ROCK DRILL LUBRICANTS – NORMAL CONDITIONS
Source Type Pour Point Maximum

Amoco Amoco Rock Drill Oil – Light –20_

Amoco Rock Drill Oil – Medium 0_
Arco Air Drill #147 0_
Arco Trueslide #150 15_
Chevron Oil U.S.A. Vistac #68X 10_
Vistac #100X 5_
Vistac #150X 0_
Conoco EP Rockdrill #49, #17, #78 5_
Gulf Oil (Chevron) Rockdrill #100 –30_
Rockdrill #32 –35_
Exxon Arox EP #46 –20_
Arox #150 –35_
Mobil Oil Co. Almo #525 –20_
Almo #527 –20_
Almo #529 –10_
Almo #532 0_
Pacer Oil Rockdrill #150 –10_
Rockdrill #600 0_
Phillips Petroleum EP #500 (Summer) or EP #300 (Winter) –10_
Shell Oil Co. Torcula Oil #32 –50_
Torcula Oil #100 –20_
Torcula Oil #150 –15_
Torcula Oil #320 –10_
Sun Oil Co. Rockdrill 500 (Light) 5_
Rockdrill 1000 (Heavy) 5_
Texaco Oil Co. Rockdrill Oil XL –40_
Rockdrill Oil XM 0_
Rockdrill Oil XH –20_
Union Oil of Ca. Marok 150 –––

STEAM CYLINDER OILS – HIGH TEMPERATURE PUMPED FLUIDS

Source Type

Amoco Amoco Cylinder Oil 460

Arco Modco Cylinder Oil 125, 175
Conoco Inca Cylinder Oil
Exxon Cylesstic TK–460 or TK–1000
Gulf Oil (Chevron) Senate #375 Compound
Security #460 Non–Compound
Mobil Oil Co. Mobil Cylinder Oil 600W
Pacer Oil Com–Cyl Oil
Phillips Petroleum Hector Cylinder Oil
Shell Oil Co. Valvata J–460
Sun Oil Co. Occident
Gear Oil 7–X, Gear Oil 8–C
Texaco Oil Co. Pinnacle Cylinder Oil

3–1–614 Page 25
 GARDNER DENVER HORIZONTAL PUMP
RECOMMENDED SYSTEM LAYOUT FOR PROPER PERFORMANCE

NOTES:
1) Feed line and bypass line openings in tank must as large as the pump suction opening. Flow veloc-
be located below the top of baffle and on opposite ity should be 3 ft/sec or less.
side of tank from outlet opening.
5) Suction and discharge lines should each contain
2) The baffle must be completely submerged at mini- a section of flexible hose to remove piping strain
mum liquid level in the tank. The baffle must be and vibration.
placed between the feed line and tank outlet to 6) The suction stabilizer should be a bladder type
pump and should extend from one side of the tank with an internal baffle between the inlet and outlet
to the other. connections.
3) If a tank baffle cannot be installed, flow into the 7) NPSH provided by suction system must be ade-
tank must be directed away from tank outlet to quate to satisfy pump requirements. Refer to
pump so entrained gasses do not flow directly into NPSHR curve or consult Gardner–Denver Mar-
tank outlet. keting.
8) A bladder type discharge pulsation dampener is
4) A short straight suction line is preferred from the
recommended.
tank to the pump. If this is not possible, use as few
bends as possible and use long radius elbows. 9) Discharge line flow velocity should be 10 ft/sec or
The smallest portion of the line should be at least less.

3–1–614 Page 26
 NET POSITIVE SUCTION HEAD REQUIRED (NPSHR)
AT FLUID CYLINDER SUCTION CONNECTION WITH SUCTION STABILIZER
AND DISCHARGE PULSATION DAMPENER INSTALLED

S Use scale (1) for models: TQC, TDD, TAE, TDE & TFE (LP & MP Aluminum Bronze)
S Use scale (2) for models: TAC & QBX
S Use scale (3) for models: TQB & TQW

Pump Bulletins list maximum and minimum plunger sizes. Interpolate between NPSH curves for each plunger size.

1) NPSHR is defined at a 3% flow drop below maximum capacity, caused by beginning cavitation.

2) These curves were generated from data recorded on test pumps using new plungers and packing. Pumps
in service will normally require NPSHR values above atmospheric pressure to avoid cavitation caused by
air being drawn into the cylinder past worn plungers and packing.

3) Added suction head above that shown by the curves must also be provided for the higher vapor pressure
of warmer water (curves are based on 60_F water) and/or other fluids, for gasses disolved in the pumped
fluid (ex. air in water), and for acceleration head and friction losses in systems having long and/or restricted
suction lines. Therefore, installed pump NPSHR will vary widely between applications of the same pump.

4) In summary, experience has shown that for most service applications, the user is well advised to design the
pump suction system to provide: a minimum 4.3 PSIG (10 ft. of water) at the pump inlet connection to mini-
mize problem cavitation.

3–1–614 Page 27
 CORRECTION CHART FOR TEMPERATURE OR VISCOSITY

PUMP SPEED – PERCENT OF MAXIMUM RATED SPEED

* Maximum allowable on Triplex and Quintuplex Models

3–1–614 Page 28
 VISCOSITY CONVERSION TABLE

This table lists a comparison of various viscosity ratings, when the viscosity is given in terms other than Saybolt
Universal, it can be translated by following horizontally to the Saybolt column.

Seconds Kinematic Seconds

Saybolt Viscosity Saybolt Seconds Seconds Seconds Seconds Seconds Seconds Seconds Seconds
Universal Centistokes Furol Redwood 1 Redwood 2 Degrees Degrees Parlin Parlin Parlin Parlin Ford Ford
ssu * ssf (Standard) (Admiralty) Engler Barbey Cup #7 Cup #10 Cup #15 Cup #20 Cup #3 Cup #4

31 1.00 ––– 29 ––– 1.00 6200 ––– ––– ––– ––– ––– –––
31 1.00 ––– 29 ––– 1.00 6200 ––– ––– ––– ––– ––– –––
35 2.56 ––– 32.1 ––– 1.16 2420 ––– ––– ––– ––– ––– –––
40 4.30 ––– 36.2 5.10 1.31 1440 ––– ––– ––– ––– ––– –––
50 7.40 ––– 44.3 5.83 1.58 838 ––– ––– ––– ––– ––– –––

60 10.3 ––– 52.3 6.77 1.88 618 ––– ––– ––– ––– ––– –––
70 13.1 12.95 60.9 7.60 2.17 483 ––– ––– ––– ––– ––– –––
80 15.7 13.70 69.2 8.44 2.45 404 ––– ––– ––– ––– ––– –––
90 18.2 14.44 77.6 9.30 2.73 348 ––– ––– ––– ––– ––– –––

100 20.6 15.24 85.6 10.12 3.02 307 ––– ––– ––– ––– ––– –––
150 32.1 19.30 128 14.48 4.48 195 ––– ––– ––– ––– ––– –––
200 43.2 23.5 170 18.90 5.92 144 40 ––– ––– ––– ––– –––
250 54.0 28.0 212 23.45 7.35 114 46 ––– ––– ––– ––– –––

300 65.0 32.5 254 28.0 8.79 95 52.5 15 6.0 3.0 30 20

400 87.60 41.9 338 37.1 11.70 70.8 66 21 7.2 3.2 42 28
500 110.0 51.6 423 46.2 14.60 56.4 79 25 7.8 3.4 50 34
600 132 61.4 508 55.4 17.50 47.0 92 30 8.5 3.6 58 40

700 154 71.1 592 64.6 20.45 40.3 106 35 9.0 3.9 67 45
800 176 81.0 677 73.8 23.35 35.2 120 39 9.8 4.1 74 50
900 198 91.0 762 83.0 26.30 31.3 135 41 10.7 4.3 82 57
1000 220 100.7 896 92.1 29.20 28.2 149 43 11.5 4.5 90 62

1500 330 150 1270 138.2 43.80 18.7 ––– 65 15.2 6.3 132 90
2000 440 200 1690 184.2 58.40 14.1 ––– 86 19.5 7.5 172 118
2500 550 250 2120 230 73.0 11.3 ––– 108 24 9 218 147
3000 660 300 2540 276 87.60 9.4 ––– 129 28.5 11 258 172

4000 880 400 3380 368 117.0 7.05 ––– 172 37 14 337 230
5000 1100 500 4230 461 146 5.64 ––– 215 47 18 425 290
6000 1320 600 5080 553 175 4.70 ––– 258 57 22 520 350
7000 1540 700 5920 645 204.5 4.03 ––– 300 67 25 600 410

8000 1760 800 6770 737 233.5 3.52 ––– 344 76 29 680 465

9000 1980 900 7620 829 263 3.13 ––– 387 86 32 780 520

10000 2200 1000 8460 921 292 2.82 ––– 430 96 35 850 575

15000 3320 1500 13700 ––– 438 2.50 ––– 650 147 53 1280 860
20000 4400 2000 18400 ––– 584 1.40 ––– 860 203 70 1715 1150

* Kinematic Viscosity (in centistokes) = Absolute viscosity (in centipoises)

Specific Gravity

Above 250 SSU, use the following approximate conversion:

SSU = Centistokes x 4.62

Above the range of this table and within the range of the viscosimeter, multiply their rating by the following factors
to convert to SSU:

Viscosimeter Factor Viscosimeter Factor

Saybolt Furol 10. Parlin cup #15 98.2

Redwood Standard 1.095 Parlin cup #20 187.0
Redwood Admiralty 10.87 Ford cup #4 17.4
Engler – Degrees 34.5

3–1–614 Page 29
SECTION 4
TROUBLE–SHOOTING

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Pump Overloads Driver. 1. Excessive pump speed 1. Reduce pump speed and/or
and/or discharge pressure. pressure.
2. Blockage or closed 2. Clean or open valve.
valve in discharge line.
3. Incorrect plunger size. 3. Install the correct
plunger.
4. Improper bypass conditions. 4. See recommended system
layout, and correct error.

Fluid Not Delivered. 1. Pump not primed. 1. Prime pump.

2. Air or vapor pocket in 2. Remove pocket from line.
suction line.
3. Clogged suction line. 3. Clean out line.
4. Suction and/or discharge 4. Remove prop.
valves propped open.

Low Discharge Pressure. 1. Worn or fluid cut valve 1. Replace valve assembly.
assembly.
2. Valve propped open. 2. Remove prop.
3. Pump cavitating. 3. See Cavitation, Fluid Knock
or Hammer problem.
4. Fluid leakage. 4. Replace plungers/packing
and/or fluid end seals.
5. Erroneous gauge reading. 5. Recalibrate or replace
gauge(s).

Low Suction Pressure. 1. Low head (NPSH). 1. Raise fluid supply level.
Install charging pump.
2. Insufficient charging pump 2. Increase charging pump
capacity. speed or size.
3. Retarded fluid flow. 3. Remove restrictions from
suction line.
4. Erroneous gauge reading. 4. Recalibrate or replace
gauge(s).

Cavitation, Fluid Knock or Hammer. 1. Improper suction system 1. See recommended system
layout. layout in manual.
2. Low suction pressure. 2. See Low Suction Pressure
problem.
3. Suction stabilizer and 3. Install suction stabilizer
pulsation dampener not used. and pulsation dampener.
4. Defective stabilizer or 4. Repair and recharge or
dampener. replace.

3–1–614 Page 30
 PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Cavitation, Fluid Knock or Hammer 5. High fluid temperature or 5. Reduce pump speed per
(continued). viscosity. chart in manual.
6. High fluid vapor pressure. 6. Increase NPSH.
7. High acceleration head. 7. Increase supply line size.
Decrease supply line length.
8. Suction valve spring too stiff 8. Use more flexible spring.
with low NPSH.
Remove inner spring from
two spring valve.
9. Air/Gas in pumped fluid. 9. Allow more settling time
in supply tank.
Reduce pump speed.
10. Air entering suction line. 10. Repair suction line.
11. Air entering charging pump. 11. Tighten or replace shaft
packing or seal.
12. Air entering or charge gas 12. Repair and recharge
escaping from suction stabilizer. stabilizer.
13. Multiple pumps operating in 13. Use a suction stabilizer
phase. on each pump. Separate
lines may also be needed.

Suction or Discharge Line Vibration. 1. Line(s) not supported. 1. Install supports or hangers.
2. Pump cavitating. 2. See Cavitation, Fluid Knock
or Hammer problem.

High Crankcase Oil Temperature. 1. High ambient temperature. 1. Use an oil heat exchanger
with a circulating pump.
2. Improper type/grade oil used. 2. Use recommended oil.
3. Pump overloaded. 3. Reduce pump speed and/or
pressure.
4. Improper clearance in main or 4. Check and adjust clearance.
rod bearings, crossheads or Replace parts as required.
bushings.

Knock In Power End. 1. Improper main bearing clearance. 1. Check and adjust clearances.
2. Incorrect pump rotation. 2. Reverse rotation.
3. Loose plunger coupling. 3. Check and tighten. Replace
if damaged.
4. Loose extension rod. 4. Check and tighten. Replace
if damaged.
5. Loose connecting rod cap. 5. Check and tighten. Replace
if damaged.
6. Loose bearing housings/covers. 6. Check and tighten. Replace
if damaged.
7. Worn crosshead pin. 7. Replace.

3–1–614 Page 31
 PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Knock In Power End (continued). 8. Worn crosshead pin bushing. 8. Replace.

9. Worn connecting rod to 9. Replace.
eccentric bearing.
10. Worn crankshaft. 10. Replace.
11. Worn crosshead. 11. Replace.
12. Worn main bearing. 12. Replace.
13. Valve noise transmitted to 13. See Excessive Valve Noise
power end. problem.
14. Cavitation noise transmitted to, 14. See Cavitation, Fluid Knock
or causing shock loading in, or Hammer problem
power end.

Excessive Valve Noise. 1. Pump cavitation. 1. See Cavitation, Fluid Knock

or Hammer problem.
2. Seal on inserted valve 2. Replaced seal or valve.
damaged or missing.
3. Broken or weak valve spring(s). 3. Replace spring(s).

Oil Leakage From Stop Head. 1. Worn, damaged or corroded 1. Replace extension rod.
extension rod.
2. Worn oil stop head packing. 2. Replace packing.
3. Oil level too high in 3. Reduce oil level.
crankcase.
4. Excessive crosshead wear. 4. Replace crosshead.
5. Pressure in crankcase. 5. Clean or replace air breather.

Oil Seal Leakage. 1. Worn sealing lip. 1. Replace seal.

2. Damaged sealing lip. 2. Replace seal.
3. O.D. not seated. 3. Clean and polish bore of
oil seal housing.
4. Shaft rough at seal lip. 4. Clean and polish shaft or
replace wear sleeve.
5. Pressure in crankcase. 5. Clean or replace air breather.

Stuffing Box Leakage. 1. Short plunger/packing life. 1. See Short Plunger/Packing

Life problem.
2. Worn packing rings/metal. 2. Replace packing rings/metal.
3. Gasket leaking at fluid 3. Check gasket, stuffing box
cylinder. groove and cylinder sealing
surface.
4. Corrosion due to wrong stuffing 4. Determine and install correct
box material for pumped fluid. stuffing box.

3–1–614 Page 32
 PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Pumped Fluid In Crankcase. 1. Worn, damaged or corroded 1. Replace extension rod.

extension rod.
2. Worn oil stop head packing. 2. Replace packing.
3. Stuffing box leakage. 3. See Stuffing Box Leakage
problem.
4. Extension rod baffles damaged/ 4. Install new baffles.
missing.

Short Valve Life. 1. Abrasives in pumped fluid. 1. Filter pumped product.

Use severe duty valves
with insert.
2. Valve not sealing. 2. Broken valve spring – replace.
Worn valve guide – replace.
Worn valve/seat – replace.
3. Pump cavitating. 3. See Cavitation, Fluid Knock or
Hammer problem.
4. Corrosion. 4. Treat pumped fluid.
Use different materials
for valves/seats.
Install sacrificial anodes
in suction manifold.

Short Plunger/Packing Life. 1. Abrasives in pumped fluid. 1. Consult GD Customer

Service for plunger/
packing recommendation.
Filter pumped fluid.
2. Excessive plunger/packing 2. Lubricate with rock drill oil.
friction.
Do not overtighten adjust–
able packing.
Use Gardner Denver plungers.
3. Metal parts or particles 3. Check stuffing box
wearing plunger. alignment.
Check gland alignment.
Check plunger alignment.
Check packing for foreign
particles.
Replace gland bushing.
Replace lantern ring.
4. Wrong plunger/packing for 4. Consult GD Customer
pumping conditions. Service.
5. Wrong size packing. 5. Install correct size packing.
6. Improper packing installation. 6. Check installation procedure
and install correctly.
7. Excessive crosshead wear. 7. Replace crosshead.
8. Pump cavitating. 8. See Cavitation, Fluid Knock
or Hammer problem.

3–1–614 Page 33
 PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Catastrophic Failures Such As 1. Pump overloaded. 1. Reduce pump speed and/or

Broken Shafts, Bent Rods, etc. pressure.
2. Start–up against closed 2. Insure valve is open
discharge valve. before starting.
3. Main bearing failure. 3. Repair or replace.
4. Plunger striking valve or 4. Check valve condition and
valve parts. installation procedure.
5. Plunger striking cylinder. 5. Check plunger for proper
length.
6. Frozen fluid in cylinder. 6. Do not start pump when
pumped fluid is below
freezing temperature.
7. Low oil level in sump. 7. Check oil level frequently,
and add oil as required.
8. Contaminated oil in sump. 8. Check oil condition
frequently.
9. Cavitation shock loading. 9. See Cavitation, Fluid Knock
or Hammer problem.

Stud Failures. 1. Catastrophic failures. 1. See Catastrophic Failures

problem.
2. Improper nut torquing. 2. Check torque specifications
and torque to correct values.
3. Stud bending due to uneven 3. Check nut seat surface for
nut seating. flatness. Rework or replace
as required.
4. Corrosive attack by pumped 4. Treat fluid or use corrosion
fluid. resistant studs.
5. Studs damaged before 5. Check condition before
installation. installation, and replace if
necessary.
6. Low strength studs. 6. Use Gardner Denver studs.

3–1–614 Page 34
SECTION 5
REBUILDING DATA AND TORQUES

PUMP DATA SHEET

MODEL: TQB (GD25T)
SPECIFICATIONS:
MAXIMUM HORSEPOWER: 27 HP (19 kW) MAXIMUM PLUNGER LOAD: 2670 LB (1210 Kg)
MAXIMUM CRANKSHAFT RPM: 600 RPM CRANKSHAFT EXTENSION:
MINIMUM CRANKSHAFT RPM: 225 RPM DIAMETER: 2.00 IN. (50.8 mm)
STROKE: 2.00 IN. (51 mm) LENGTH: 3.25 IN. (82 mm)
NUMBER OF PLUNGERS: 3 KEYWAY (L x W x H): 2–3/4 x 1/2 x 1/2
TYPE OF LUBRICATION: SPLASH PUMP WEIGHT: 570 LB (258 Kg) APPROXIMATE
OIL CAPACITY: 2.5 GAL. (9.5 LITERS)

STANDARD FLUID CYLINDERS:

Max Plunger Min Plunger

Size Pressure Size Pressure
In. PSI In. PSI Standard Connections
Description (mm) (Kg/Cm2) (mm) (Kg/Cm2) Suction Discharge

TQBA – LP ALUMINUM BRONZE 2–1/4 670 1 2250 2.5” NPT 2” NPT

(TAPERED SEAT VALVES) (57) (47) (25) (158) (63.5 mm) (50.8 mm)

TQBB – LP NODULAR IRON 2–1/4 670 1 2250 2.5” NPT 2” NPT

(TAPERED SEAT VALVES) (57) (47) (25) (158) (63.5 mm) (50.8 mm)

TQBC – LP STAINLESS STEEL 2–1/4 670 1 2250 3”–3000# 2”–3000#

(TAPERED SEAT VALVES) (57) (47) (25) (158) SAE 4 BOLT SAE 4 BOLT
FLANGE FLANGE

TQBD – LP BLOCK STEEL 2–1/4 670 1 2250 3”–900# 2”–1500#

(TAPERED SEAT VALVES) (57) (47) (25) (158) ANSI RTJ ANSI RTJ
FLANGE FLANGE

3–1–614 Page 35
 REBUILDING DATA FOR TQB (GD25T) PUMPS

PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TQB (GD25T) TQB (GD25T)

PUMP STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IN. 50.8 mm

INCHES METRIC (mm)

Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.623/2.624 66.624/66.650

Crankpin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.504/1.515 38.202/38.481
Crankshaft Diameter at Main Bearing . . . . . . . . . . . . . . . . 2.126/2.127 54.000/54.026
Distance Between Main Bearings . . . . . . . . . . . . . . . . . . . . 13.750/13.760 349.250/349.504
Bore in Housing for Main Bearing . . . . . . . . . . . . . . . . . . . 4.248/4.250 107.899/107.950
Connecting Rod Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 139.7
Bore in Connecting Rod for Crosshead Pin . . . . . . . . . . . 1.0065/1.0075 25.5651/25.5905
Bore in Connecting Rod for Insert . . . . . . . . . . . . . . . . . . . 2.775/2.776 70.485/70.510
Crosshead Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0080/1.0082 25.6032/25.6083
Crosshead Pin Bushing Bore (Honed) . . . . . . . . . . . . . . . 1.0095/1.0100 25.6413/25.6540
Bore in Crosshead for Bushing . . . . . . . . . . . . . . . . . . . . . . 1.249/1.250 31.725/31.750

RUNNING CLEARANCES – ACTUAL*:

Crankpin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0006/.0036 .0152/.0914

Crankpin Bearing Width Clearance . . . . . . . . . . . . . . . .007/.023 .178/.584
Crosshead Pin to Bushing . . . . . . . . . . . . . . . . . . . . . . .0013/.0020 .0330/.0508
Main Bearing End Clearance . . . . . . . . . . . . . . . . . . . . .002/.004 .051/.102
Crosshead to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .006/.010 .152/.254

* Feeler gauge clearances .001 inch or .025 mm less than actual values.

3–1–614 Page 36
 TQB (GD25T)
MODEL TQBA TQBB TQBC TQBD
DESCRIPTION LP ALUMINUM BRONZE LP NODULAR IRON LP STAINLESS STEEL LP BLOCK STEEL

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 3.125 (79.375) 3.125 (79.375) 3.125 (79.375) 3.125 (79.375)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 2.625 (66.675) 2.625 (66.675) 2.625 (66.675) 2.625 (66.675)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 5/8–11 (15.8) 5/8–11 (15.8) 5/8–11 (15.8) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 180 (245) 180 (245) 180 (245) 180 (245)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 5/8–11 (15.8) 5/8–11 (15.8) 5/8–11 (15.8) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 75 (100) 75 (100) 75 (100) 75 (100)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 3/4–10 (19.0) 3/4–10 (19.0) 3/4–10 (19.0)
TORQUE–DRY FT–LB (Nm) 260 (352) 260 (352) 260 (352) 260 (352)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) N/A N/A N/A 7/8–9 (22.2)
TORQUE–DRY FT–LB (Nm) 430 (583)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A 3/4–10 (19.0)
Page 37

TORQUE–DRY FT–LB (Nm) 260 (352)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) N/A N/A N/A 7/8–9 (22.2)
TORQUE–DRY FT–LB (Nm) 430 (583)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 15 (20) 15 (20) 15 (20) 15 (20)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) 40 (54)
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) 40 (54)
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27) 20 (27) 20 (27)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (102) 75 (102) 75 (102) 75 (102)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) N/A N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) N/A N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
 PUMP DATA SHEET
MODEL: TQW (GD45T)

SPECIFICATIONS:
MAXIMUM HORSEPOWER: 45 HP (34 kW) MAXIMUM PLUNGER LOAD: 3770 LB (1710 Kg)
MAXIMUM CRANKSHAFT RPM: 575 RPM CRANKSHAFT EXTENSION:
MINIMUM CRANKSHAFT RPM: 225 RPM DIAMETER: 2.5 IN. (63.5 mm)
STROKE: 2.50 IN. (63 mm) LENGTH: 4.12 IN. (105 mm)
NUMBER OF PLUNGERS: 3 KEYWAY (L x W x H): 2–3/4 x 5/8 x 5/8
TYPE OF LUBRICATION: SPLASH PUMP WEIGHT: 775 LB (352 Kg) APPROXIMATE
OIL CAPACITY: 4 GAL. (15 LITERS)

STANDARD FLUID CYLINDERS:

Max Plunger Min Plunger

Size Pressure Size Pressure
In. PSI In. PSI Standard Connections
Description (mm) (Kg/Cm2) (mm) (Kg/Cm2) Suction Discharge

TQWA – LP ALUMINUM BRONZE 2–3/4 635 1–3/4 1380 2.5” NPT 2” NPT
(TAPERED SEAT VALVES) (70) (44) (44) (97) (63.5 mm) (50.8 mm)

TQWB – HP ALUMINUM BRONZE 1–1/2 1900 7/8 5000 3” NPT 2” NPT

(TAPERED SEAT VALVES) (38) (135) (22) (352) (63.5 mm) (50.8 mm)

TQWC – LP NODULAR IRON 2–3/4 635 1–3/4 1380 2.5” NPT 2” NPT
(TAPERED SEAT VALVES) (70) (44) (44) (97) (63.5 mm) (50.8 mm)

TQWD – LP BLOCK STEEL 2–3/4 635 1–3/4 2250 3”–900# 2”–1500#

(TAPERED SEAT VALVES) (70) (44) (44) (158) ANSI RTJ ANSI RTJ
FLANGE FLANGE

TQWE – LP STAINLESS STEEL 2–3/4 635 1–3/4 2250 2.5”–3000# 2”–3000#

(TAPERED SEAT VALVES) (70) (44) (44) (158) SAE 4 BOLT SAE 4 BOLT
FLANGE FLANGE

3–1–614 Page 38
 REBUILDING DATA FOR TQW (GD45T) PUMPS

PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TQW (GD45T) TQW (GD45T)

PUMP STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1/2 IN. 63.5 mm

INCHES METRIC (mm)

Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.999/3.000 76.175/76.200

Crankpin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.879/1.890 47.727/48.006
Crankshaft Diameter at Main Bearing . . . . . . . . . . . . . . . . 2.626/2.627 66.700/66.726
Distance Between Main Bearings . . . . . . . . . . . . . . . . . . . . 15.000/15.010 381.000/381.254
Bore in Housing for Main Bearing . . . . . . . . . . . . . . . . . . . 4.8105/4.8125 122.1867/122.2375
Connecting Rod Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.875 174.625
Bore in Connecting Rod for Crosshead Pin . . . . . . . . . . . 1.2565/1.2575 31.9151/31.9405
Bore in Connecting Rod for Insert . . . . . . . . . . . . . . . . . . . 3.194/3.195 81.128/81.153
Crosshead Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2580/1.2582 31.9532/31.9583
Crosshead Pin Bushing Bore (Honed) . . . . . . . . . . . . . . . 1.2595/1.2600 31.9913/32.0040
Bore in Crosshead for Bushing . . . . . . . . . . . . . . . . . . . . . . 1.499/1.500 38.075/38.100

RUNNING CLEARANCES – ACTUAL*:

Crankpin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008/.0038 .0203/.0965

Crankpin Bearing Width Clearance . . . . . . . . . . . . . . . .007/.023 .178/.584
Crosshead Pin to Bushing . . . . . . . . . . . . . . . . . . . . . . .0013/.0020 .0330/.0508
Main Bearing End Clearance . . . . . . . . . . . . . . . . . . . . .002/.004 .051/.102
Crosshead to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .006/.010 .152/.254

* Feeler gauge clearances .001 inch or .025 mm less than actual values.

3–1–614 Page 39
 TQW (GD45T)
MODEL TQWA TQWB TQWC TQWD TQWE
DESCRIPTION LP ALUMINUM BRONZE HP ALUMINUM BRONZE LP NODULAR IRON LP BLOCK STEEL LP STAINLESS STEEL

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 3.125 (79.375) 2.250 (57.150) 3.125 (79.375) 3.125 (79.375) 3.125 (79.375)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 2.00 (50.8) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 2.625 (66.675) 1.500 (38.100) 2.625 (66.675) 2.625 (66.675) 2.625 (66.675)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 2.00 (50.8) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 5/8–11 (15.8) 3/4–10 (19.0) 5/8–11 (15.8) 5/8–11 (15.8) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 180 (245) 300 (407) 180 (245) 180 (245) 180 (245)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 5/8–11 (15.8) 3/4–10 (19.0) 5/8–11 (15.8) 5/8–11 (15.8) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 100 (135) 150 (205) 100 (135) 100 (135) 100 (135)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 5/8–11 (15.8) 3/4–10 (19.0) 3/4–10 (19.0) 3/4–10 (19.0)
TORQUE–DRY FT–LB (Nm) 260 (352) 150 (203) 260 (352) 260 (352) 260 (352)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) N/A N/A N/A 7/8–9 (22.2) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 430 (583) 110 (14.9)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A N/A N/A
Page 40

TORQUE–DRY FT–LB (Nm)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A 1/2–13 (12.7) N/A N/A N/A
TORQUE–DRY FT–LB (Nm) 75 (102)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) N/A N/A N/A 7/8–9 (22.2) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 430 (583) 110 (149)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 15 (20) 15 (20) 15 (20) 15 (20) 15 (20)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) 40 (54) 40 (54)
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) 40 (54) 40 (54)
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27) 20 (27) 20 (27) 20 (27)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (102) 75 (102) 75 (102) 75 (102) 75 (102)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) N/A N/A N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) N/A N/A N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
 PUMP DATA SHEET
MODEL: TQC (GD50T)

SPECIFICATIONS:
MAXIMUM HORSEPOWER: 50 HP (37 kW) MAXIMUM PLUNGER LOAD: 4948 LB (2249 Kg)
MAXIMUM CRANKSHAFT RPM: 400 RPM CRANKSHAFT EXTENSION:
MINIMUM CRANKSHAFT RPM: 200 RPM DIAMETER: 2.625 IN. (66.7 mm)
STROKE: 3.00 IN. (76 mm) LENGTH: 4.12 IN. (105 mm)
NUMBER OF PLUNGERS: 3 KEYWAY (L x W x H): 3–1/2 x 5/8 x 5/8
TYPE OF LUBRICATION: SPLASH PUMP WEIGHT: 970 LB (440 Kg) APPROXIMATE
OIL CAPACITY: 6.5 GAL. (25 LITERS)

STANDARD FLUID CYLINDERS:

Max Plunger Min Plunger

Size Pressure Size Pressure
In. PSI In. PSI Standard Connections
Description (mm) (Kg/Cm2) (mm) (Kg/Cm2) Suction Discharge

TQCB – LP BLOCK STEEL 3 700 1–3/4 2058 3”–900# 2”–1500#

(TAPERED SEAT VALVES) (76) (48) (44) (142) ANSI RTJ ANSI RTJ
FLANGE FLANGE

TQCC – LP STAINLESS STEEL 3 700 1–3/4 2058 3”–3000# 2”–3000#

(TAPERED SEAT VALVES) (76) (48) (44) (142) SAE 4 BOLT SAE 4 BOLT
FLANGE FLANGE

TQCD – LP ALUMINUM BRONZE 3 700 1–3/4 2058 3” NPT 2” NPT

(TAPERED SEAT VALVES) (76) (48) (44) (142) (76.2 mm) (50.8 mm)

3–1–614 Page 41
 REBUILDING DATA FOR TQC (GD50T) PUMPS

PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TQC (GD50T) TQC (GD50T)

PUMP STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 IN. 76.2 mm

INCHES METRIC (mm)

Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.249/3.250 82.525/82.550

Crankpin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.504/2.515 63.602/63.881
Crankshaft Diameter at Main Bearing . . . . . . . . . . . . . . . . 2.814/2.815 71.476/71.501
Distance Between Main Bearings . . . . . . . . . . . . . . . . . . . . 17.750/17.760 450.850/451.104
Bore in Housing for Main Bearing . . . . . . . . . . . . . . . . . . . 5.373/5.375 136.474/136.525
Connecting Rod Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.250 209.550
Bore in Connecting Rod for Crosshead Pin . . . . . . . . . . . 1.5065/1.5075 38.2651/38.2905
Bore in Connecting Rod for Insert . . . . . . . . . . . . . . . . . . . 3.444/3.445 87.478/87.503
Crosshead Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5080/1.5082 38.3032/38.3083
Crosshead Pin Bushing Bore (Honed) . . . . . . . . . . . . . . . 1.5090/1.5095 38.3286/38.3413
Bore in Crosshead for Bushing . . . . . . . . . . . . . . . . . . . . . . 1.749/1.750 44.425/44.450

RUNNING CLEARANCES – ACTUAL*:

Crankpin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008/.0048 .0203/.1219

Crankpin Bearing Width Clearance . . . . . . . . . . . . . . . .007/.023 .178/.584
Crosshead Pin to Bushing . . . . . . . . . . . . . . . . . . . . . . .0008/.0015 .0203/.0381
Main Bearing End Clearance . . . . . . . . . . . . . . . . . . . . .002/.004 .051/.102
Crosshead to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .006/.010 .152/.254

* Feeler gauge clearances .001 inch or .025 mm less than actual values.

3–1–614 Page 42
 TQC (GD50T)
MODEL TQCB TQCC TQCD
DESCRIPTION LP BLOCK STEEL LP STAINLESS STEEL LP ALUMINUM BRONZE

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 3.125 (79.375) 3.125 (79.375) 2.625 (66.675)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 2.625 (66.675) 2.625 (66.675) 2.625 (66.675)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 5/8–11 (15.8) 5/8–11 (15.8) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 180 (245) 180 (245) 180 (245)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 90 (122) 90 (122) 90 (122)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 3/4–10 (19.0) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 260 (352) 260 (352) 175 (237)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) 7/8–9 (22.2) 1/2–13 (12.7) N/A
TORQUE–DRY FT–LB (Nm) 430 (583) 110 (149)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A N/A 5/8–11 (15.8)
Page 43

TORQUE–DRY FT–LB (Nm) 175 (237)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) 7/8–9 (22.2) 5/8–11 (15.8) N/A
TORQUE–DRY FT–LB (Nm) 430 (583) 220 (298)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 15 (20) 15 (20) 15 (20)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54)
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54)
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27) 20 (27)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (102) 75 (102) 75 (102)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) 7/8–9 (22.2) 7/8–9 (22.2) 7/8–9 (22.2)
TORQUE–DRY FT–LB (Nm) 75–100 (102–136) 75–100 (102–136) 75–100 (102–136)
 PUMP DATA SHEET
MODEL: TAC (GD60T)

SPECIFICATIONS:
MAXIMUM HORSEPOWER: 60 HP (45 kW) MAXIMUM PLUNGER LOAD: 4752 LB (2160 Kg)
MAXIMUM CRANKSHAFT RPM: 500 RPM CRANKSHAFT EXTENSION:
MINIMUM CRANKSHAFT RPM: 175 RPM DIAMETER: 2.625 IN. (66.7 mm)
STROKE: 3.00 IN. (76 mm) LENGTH: 5.00 IN. (127 mm)
NUMBER OF PLUNGERS: 3 KEYWAY (L x W x H): 4–3/8 x 5/8 x 5/8
TYPE OF LUBRICATION: SPLASH PUMP WEIGHT: 1790 LB (812 Kg) APPROXIMATE
OIL CAPACITY: 6 GAL. (23 LITERS)

STANDARD FLUID CYLINDERS:

Max Plunger Min Plunger
Size Pressure Size Pressure
In. PSI In. PSI Standard Connections
Description (mm) (Kg/Cm2) (mm) (Kg/Cm2) Suction Discharge

TACA – LP ALUMINUM BRONZE 3 675 1–3/4 2000 3”–150# 2”–1500#

(TAPERED SEAT VALVES) (76) (47) (44) (137) ANSI ANSI
FLANGE FLANGE

TACB – HP ALUMINUM BRONZE 1–1/2 2680 1 5000 3”–150# 1.5”–2500#

(TAPERED SEAT VALVES) (38) (185) (25) (345) ANSI ANSI
FLANGE FLANGE

TACC – MP BLOCK STEEL 2–1/4 1190 1–3/4 2000 3”–900# 2”–1500#

(TAPERED SEAT VALVES) (57) (82) (44) (137) ANSI ANSI
FLANGE FLANGE

TACD – MP STAINLESS STEEL 2–1/4 1190 1–3/4 2000 3”–3000# 2”–3000#

(TAPERED SEAT VALVES) (57) (82) (44) (137) SAE 4 BOLT SAE 4 BOLT
FLANGE FLANGE

TACE – LP BLOCK STEEL 3 675 1–1/2 2220 3”–900# 2”–1500#

(TAPERED SEAT VALVES) (76) (47) (38) (153) ANSI ANSI RTJ
FLANGE FLANGE

TACF – LP STAINLESS STEEL 3 675 1–1/2 2220 3”–3000# 2”–3000#

(TAPERED SEAT VALVES) (76) (47) (38) (153) SAE 4 BOLT SAE 4 BOLT
FLANGE FLANGE

3–1–614 Page 44
 REBUILDING DATA FOR TAC (GD60T) PUMPS

PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAC (GD60T) TAC (GD60T)

PUMP STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 IN. 76.2 mm

INCHES METRIC (mm)

Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.248/3.249 82.499/82.525

Crankpin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.504/2.515 63.601/63.881
Crankshaft Diameter at Main Bearing . . . . . . . . . . . . . . . . 2.8765/2.8775 73.0631/73.0885
Distance Between Main Bearings . . . . . . . . . . . . . . . . . . . . 17.750/17.760 450.850/451.104
Bore in Housing for Main Bearing . . . . . . . . . . . . . . . . . . . 5.873/5.875 149.174/149.225
Connecting Rod Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.250 209.550
Bore in Connecting Rod for Crosshead Pin . . . . . . . . . . . 1.5065/1.5075 38.2651/38.2905
Bore in Connecting Rod for Insert . . . . . . . . . . . . . . . . . . . 3.444/3.445 87.478/87.503
Crosshead Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5080/1.5082 38.3032/38.3083
Crosshead Pin Bushing Bore (Honed) . . . . . . . . . . . . . . . 1.5090/1.5095 38.3286/38.3413
Bore in Crosshead for Bushing . . . . . . . . . . . . . . . . . . . . . . 1.749/1.750 44.425/44.450

RUNNING CLEARANCES – ACTUAL*:

Crankpin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008/.0048 .0203/.1219

Crankpin Bearing Width Clearance . . . . . . . . . . . . . . . .007/.023 .178/.584
Crosshead Pin to Bushing . . . . . . . . . . . . . . . . . . . . . . .0008/.0015 .0203/.0381
Main Bearing End Clearance . . . . . . . . . . . . . . . . . . . . .002/.004 .051/.102
Crosshead to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .006/.010 .152/.254

* Feeler gauge clearances .001 inch or .025 mm less than actual values.

3–1–614 Page 45
 TAC (GD60T)
MODEL TACA TACB TACC
DESCRIPTION LP ALUMINUM BRONZE LP ALUMINUM BRONZE MP BLOCK STEEL

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 4.125 (104.775) 2.375 (60.325) 3.125 (79.375)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 3.125 (79.375) 1.625 (41.275) 2.625 (66.675)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 3/4–10 (19.0) 3/4–10 (19.0)
TORQUE–DRY FT–LB (Nm) 300 (407) 300 (407) 300 (407)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 3/4–10 (19.0) 3/4–10 (19.0)
TORQUE–DRY FT–LB (Nm) 300 (407) 300 (407) 300 (407)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 7/8–9 (22.2) 3/4–10 (19.0)
TORQUE–DRY FT–LB (Nm) 300 (407) 430 (583) 300 (407)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) 7/8–9 (22.2) 1–1/8–7 (28.6) 7/8–9 (22.2)
TORQUE–DRY FT–LB (Nm) 430 (583) 800 (1084) 430 (583)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A N/A 3/4–10 (19.0)
Page 46

TORQUE–DRY FT–LB (Nm) 300 (406)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A 1/2–13 (12.7) N/A
TORQUE–DRY FT–LB (Nm) 75 (102)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) 5/8–11 (15.8) 5/8–11 (15.8) 7/8–9 (22.2)
TORQUE–DRY FT–LB (Nm) 150 (203) 150 (203) 430 (583)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 20 (27) 15 (20) 15 (20)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54)
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54)
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27) 20 (27)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (102) 75 (102) 75 (102)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
 TAC (GD60T) (Continued)
MODEL TACD TACE TACF
DESCRIPTION MP STAINLESS STEEL LP BLOCK STEEL LP STAINLESS STEEL

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 3.125 (79.375) 4.125 (104.775) 4.125 (104.775)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 2.625 (66.675) 3.125 (79.375) 3.125 (79.375)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10)
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 3/4–10 (19.0) 3/4–10 (19.0)
TORQUE–DRY FT–LB (Nm) 300 (407) 300 (407) 300 (407)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 3/4–10 (19.0) 3/4–10 (19.0)
TORQUE–DRY FT–LB (Nm) 300 (407) 300 (407) 300 (407)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 3/4–10 (19.0) 3/4–10 (19.0)
TORQUE–DRY FT–LB (Nm) 300 (407) 300 (407) 300 (407)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) 1/2–13 (12.7) 7/8–9 (22.2) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 110 (149) 430 (583) 110 (149)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A 3/4–10 (19.0) N/A
Page 47

TORQUE–DRY FT–LB (Nm) 300 (406)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) 5/8–11 (15.8) 7/8–9 (22.2) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 220 (298) 430 (583) 220 (298)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 3/8–16 (9.5) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 15 (20) 20 (27) 20 (27)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54)
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54)
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27) 20 (27)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (102) 75 (102) 75 (102)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) N/A N/A N/A
TORQUE–DRY FT–LB (Nm)
 PUMP DATA SHEET
MODEL: TDD (GD100T)

SPECIFICATIONS:
MAXIMUM HORSEPOWER: 103 HP (77 kW) MAXIMUM PLUNGER LOAD: 7175 LB (3255 Kg)
MAXIMUM CRANKSHAFT RPM: 425 RPM CRANKSHAFT EXTENSION:
MINIMUM CRANKSHAFT RPM: 175 RPM DIAMETER: 2.875 IN. (73.0 mm)
STROKE: 4.00 IN. (102 mm) LENGTH: 6.00 IN. (152 mm)
NUMBER OF PLUNGERS: 3 KEYWAY (L x W x H): 5 x 3/4 x 3/4
TYPE OF LUBRICATION: SPLASH PUMP WEIGHT: 2900 LB (1315 Kg) APPROXIMATE
OIL CAPACITY: 10.5 GAL. (40 LITERS)

STANDARD FLUID CYLINDERS:

Max Plunger Min Plunger

Size Pressure Size Pressure
In. PSI In. PSI Standard Connections
Description (mm) (Kg/Cm2) (mm) (Kg/Cm2) Suction Discharge

TDDA – LP ALUMINUM BRONZE 3–1/2 745 2–1/2 1460 4”–150# 3”–600#

(TAPERED SEAT VALVES) (89) (52) (64) (103) ANSI ANSI
FLANGE FLANGE

TDDB – MP ALUMINUM BRONZE 2–1/2 1460 1–3/4 2980 3”–150# 2”–1500#

(TAPERED SEAT VALVES) (64) (103) (44) (209) ANSI ANSI
FLANGE FLANGE

3–1–614 Page 48
 REBUILDING DATA FOR TDD (GD100T) PUMPS

PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDD (GD100T) TDD (GD100T)

PUMP STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 IN. 101.6 mm

INCHES METRIC (mm)

Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.999/4.000 101.575/101.600

Crankpin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.004/3.015 76.302/76.581
Crankshaft Diameter at Main Bearing . . . . . . . . . . . . . . . . 3.0015/3.0025 76.2381/76.2635
Distance Between Main Bearings . . . . . . . . . . . . . . . . . . . . 19.500/19.510 495.300/495.554
Bore in Housing for Main Bearing . . . . . . . . . . . . . . . . . . . 7.498/7.500 190.449/190.500
Connecting Rod Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500 266.700
Bore in Connecting Rod for Crosshead Pin . . . . . . . . . . . 2.0065/2.0075 50.9651/50.9905
Bore in Connecting Rod for Insert . . . . . . . . . . . . . . . . . . . 4.193/4.194 106.502/106.528
Crosshead Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0080/2.0085 51.0032/51.0159
Crosshead Pin Bushing Bore (Honed) . . . . . . . . . . . . . . . 2.0090/2.0095 51.0286/51.0413
Bore in Crosshead for Bushing . . . . . . . . . . . . . . . . . . . . . . 2.249/2.250 57.125/57.150

RUNNING CLEARANCES – ACTUAL*:

Crankpin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0010/.0040 .0254/.1016

Crankpin Bearing Width Clearance . . . . . . . . . . . . . . . .007/.023 .178/.584
Crosshead Pin to Bushing . . . . . . . . . . . . . . . . . . . . . . .0005/.0015 .0127/.0381
Main Bearing End Clearance . . . . . . . . . . . . . . . . . . . . .002/.004 .051/.102
Crosshead to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .006/.010 .152/.254

* Feeler gauge clearances .001 inch or .025 mm less than actual values.

3–1–614 Page 49
 TDD (GD100T)
MODEL TDDA TDDB
DESCRIPTION LP ALUMINUM BRONZE MP ALUMINUM BRONZE

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 4.256 (108.1) 3.172 (80.6)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10)
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 3.298 (83.8) 2.859 (72.6)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10)
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 1–8 (25.4) 1–8 (25.4)
TORQUE–DRY FT–LB (Nm) 700 (950) 700 (950)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 5/8–11 (15.8) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 180 (245) 180 (245)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 1–1/8–7 (28.6) 1–1/8–7 (28.6)
TORQUE–DRY FT–LB (Nm) 1000 (1355) 1000 (1355)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A
TORQUE–DRY FT–LB (Nm)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) 3/4–10 (19.0) 7/8–9 (22.2)
TORQUE–DRY FT–LB (Nm) 260 (352) 430 (583)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A N/A
Page 50

TORQUE–DRY FT–LB (Nm)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (102)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) 5/8–11 (15.8) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 150 (203) 150 (203)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 20 (27) 15 (20)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54)
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54)
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (102) 75 (102)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) N/A N/A
TORQUE–DRY FT–LB (Nm)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) 1–3/8–6 (34.9) 1–3/8–6 (34.9)
TORQUE–DRY FT–LB (Nm) 100–150 (136–204) 100–150 (136–204)
 PUMP DATA SHEET
MODEL: QBX (GD135Q)

SPECIFICATIONS:
MAXIMUM HORSEPOWER: 135 HP (101 kW) MAXIMUM PLUNGER LOAD: 5500 LB (2495 Kg)
MAXIMUM CRANKSHAFT RPM: 500 RPM CRANKSHAFT EXTENSION:
MINIMUM CRANKSHAFT RPM: 175 RPM DIAMETER: 3.00 IN. (76.2 mm)
STROKE: 3.50 IN. (88.9 mm) LENGTH: 5.50 IN. (139.7 mm)
NUMBER OF PLUNGERS: 3 KEYWAY (L x W x H): 5 x .75 x .75
TYPE OF LUBRICATION: SPLASH PUMP WEIGHT: 1875 LB (851 Kg) APPROXIMATE
OIL CAPACITY: 10.0 GAL. (38 LITERS)

STANDARD FLUID CYLINDERS:

Max Plunger Min Plunger

Size Pressure Size Pressure
In. PSI In. PSI Standard Connections
Description (mm) (Kg/Cm2) (mm) (Kg/Cm2) Suction Discharge

QBXA – LP ALUMINUM BRONZE 3 778 2 1480 6”–150# 3”–600#

(TAPERED SEAT VALVES) (76) (55) (51) (104) ANSI ANSI
FLANGE FLANGE

QBXB – MP ALUMINUM BRONZE 2–1/4 1383 1–1/2 3111 4”–150# 3”–1500#

(TAPERED SEAT VALVES) (57) (97) (38) (218) ANSI ANSI
FLANGE FLANGE

3–1–614 Page 51
 REBUILDING DATA FOR QBX (GD135Q) PUMPS

PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QBX (GD135Q) QBX (GD135Q)

PUMP STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 IN. 88.9 mm

INCHES METRIC (mm)

Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.498/3.499 88.849/88.875

Crankpin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.504/2.515 63.602/63.881
Crankshaft Diameter at Main Bearing . . . . . . . . . . . . . . . . 3.5015/3.5025 88.9381/88.9635
Distance Between Main Bearings . . . . . . . . . . . . . . . . . . . . 7.4810/7.4815 190.0174/190.0301
Bore in Housing for Main Bearing . . . . . . . . . . . . . . . . . . . 5.873/5.875 149.174/149.225
Connecting Rod Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30 236.22
Bore in Connecting Rod for Crosshead Pin . . . . . . . . . . . 1.5065/1.5075 38.2651/38.2905
Bore in Connecting Rod for Insert . . . . . . . . . . . . . . . . . . . 3.694/3.695 93.828/93.853
Crosshead Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5080/1.5085 38.3032/38.3159
Crosshead Pin Bushing Bore (Honed) . . . . . . . . . . . . . . . 1.5090/1.5095 38.3286/38.3413
Bore in Crosshead for Bushing . . . . . . . . . . . . . . . . . . . . . . 1.749/1.750 44.425/44.450

RUNNING CLEARANCES – ACTUAL*:

Crankpin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008/.0048 .0203/.1219

Crankpin Bearing Width Clearance . . . . . . . . . . . . . . . .007/.023 .178/.584
Crosshead Pin to Bushing . . . . . . . . . . . . . . . . . . . . . . .0008/.0015 .0203/.0381
Main Bearing End Clearance . . . . . . . . . . . . . . . . . . . . .002/.004 .051/.102
Crosshead to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .006/.010 .152/.254

* Feeler gauge clearances .001 inch or .025 mm less than actual values.

3–1–614 Page 52
 QBX (GD135Q)
MODEL QBXA QBXB
DESCRIPTION LP ALUMINUM BRONZE MP ALUMINUM BRONZE

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 3.172 (80.569) 2.859 (72.618)
GAGE DIAMETER – IN/FT (mm/M) 1.500 (38.10) 1.500 (38.10)
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 2.859 (72.618) 2.375 (60.325)
GAGE DIAMETER – IN/FT (mm/M) 1.500 (38.10) 1.500 (38.10)
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 3/4–10 (19.0)
TORQUE–DRY FT–LB (Nm) 300 (407) 300 (407)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 90 (122) 90 (122)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 1–1/8–7 (28.6) 1–1/8–7 (28.6)
TORQUE–DRY FT–LB (Nm) 1000 (1355) 1000 (1355)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A
TORQUE–DRY FT–LB (Nm)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) 3/4–10 (19.0) 7/8–9 (22.2)
TORQUE–DRY FT–LB (Nm) 260 (352) 430 (583)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A N/A
Page 53

TORQUE–DRY FT–LB (Nm)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A
TORQUE–DRY FT–LB (Nm)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) 3/4–10 (19.0) 5/8–11 (15.8)
TORQUE–DRY FT–LB (Nm) 260 (352) 150 (203)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (15.8) 1/2–13 (15.8)
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54)
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54)
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 3/8–16 (9.5) 3/8–16 (9.5)
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (102) 75 (102)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) N/A N/A
TORQUE–DRY FT–LB (Nm)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) 7/8–9 (22.2) 7/8–9 (22.2)
TORQUE–DRY FT–LB (Nm) 75–100 (102–136) 75–100 (102–136)
 PUMP DATA SHEET
MODEL: TAE (GD150T)

SPECIFICATIONS:
MAXIMUM HORSEPOWER: 150 HP (112 kW) MAXIMUM PLUNGER LOAD: 9633 LB (4378 Kg)
MAXIMUM CRANKSHAFT RPM: 370 RPM CRANKSHAFT EXTENSION:
MINIMUM CRANKSHAFT RPM: 175 RPM DIAMETER: 4.00 IN. (101.6 mm)
STROKE: 5.00 IN. (127 mm) LENGTH: 8.00 IN. (202 mm)
NUMBER OF PLUNGERS: 3 KEYWAY (L x W x H): 7–1/8 x 1 x 1
TYPE OF LUBRICATION: SPLASH PUMP WEIGHT: 3032 LB (1375 Kg) APPROXIMATE
OIL CAPACITY: 14.5 GAL. (55 LITERS)

STANDARD FLUID CYLINDERS:

Max Plunger Min Plunger

Size Pressure Size Pressure
In. PSI In. PSI Standard Connections
Description (mm) (Kg/Cm2) (mm) (Kg/Cm2) Suction Discharge

TAEF – LP ALUMINUM BRONZE 4–1/4 680 3 1365 6”–150# 3”–2000#

(TAPERED SEAT VALVES) (108) (48) (76) (96) ANSI API RJ
FLANGE FLANGE

TAEG – MP ALUMINUM BRONZE 3 1365 2 3065 4”–150# 2”–1500#

(TAPERED SEAT VALVES) (76) (96) (51) (216) ANSI ANSI
FLANGE FLANGE

TAEH – HP BLOCK STEEL 2 3065 1–1/4 7845 3”–300# 1–13/16” API

(TAPERED SEAT VALVES) (54) (216) (32) (552) ANSI 10000# RJ
FLANGE FLANGE

TAEL – HP BLOCK STEEL 2 3065 1–1/4 7500 3”–3000# (4) 3/4” Bolts
(CLAMPED IN VALVES) (54) (216) (32) (528) SAE 4 Bolt 4.50 DBC
FLANGE SPECIAL
TAEM – STEEL–EXTRA HIGH 1–1/2 5445 1 12000 2”–3000# (4) 3/4” Bolts
PRESSURE BLOCK (38) (383) (25) (842) SAE 4 Bolt 4.50 DBC
(CLAMPED IN VALVES) FLANGE SPECIAL

3–1–614 Page 54
 REBUILDING DATA FOR TAE (GD150T) PUMPS

PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAE (GD150T) TAE (GD150T)

PUMP STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IN. 127 mm

INCHES METRIC (mm)

Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.998/4.999 126.949/126.975

Crankpin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.504/3.515 89.002/89.281
Crankshaft Diameter at Main Bearing . . . . . . . . . . . . . . . . 4.2515/4.2525 107.9881/108.0135
Distance Between Main Bearings . . . . . . . . . . . . . . . . . . . . 21.875/21.885 555.625/555.879
Bore in Housing for Main Bearing . . . . . . . . . . . . . . . . . . . 8.373/8.375 212.674/212.725
Connecting Rod Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0625 331.7875
Bore in Connecting Rod for Crosshead Pin . . . . . . . . . . . 3.000/3.002 76.200/76.251
Bore in Connecting Rod for Insert . . . . . . . . . . . . . . . . . . . 5.224/5.225 132.690/132.715
Crosshead Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0000/3.0005 76.2000/76.2127
Crosshead Pin Bushing Bore (Honed) . . . . . . . . . . . . . . . 3.0015/3.0020 76.2381/76.2508
Bore in Crosshead for Bushing . . . . . . . . . . . . . . . . . . . . . . 3.374/3.375 85.699/85.725

RUNNING CLEARANCES – ACTUAL*:

Crankpin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0022/.0056 .0559/.1422

Crankpin Bearing Width Clearance . . . . . . . . . . . . . . . .007/.023 .178/.584
Crosshead Pin to Bushing . . . . . . . . . . . . . . . . . . . . . . .0010/.0020 .0254/.0508
Main Bearing End Clearance . . . . . . . . . . . . . . . . . . . . .002/.004 .051/.102
Crosshead to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .006/.011 .152/.279

* Feeler gauge clearances .001 inch or .025 mm less than actual values.

3–1–614 Page 55
 TAE (GD150T)
MODEL TAEF TAEG TAEH TAEL TAEM
DESCRIPTION LP ALUM BRONZE MP ALUM BRONZE LP BLOCK STEEL HP BLOCK STEEL XHP BLOCK STEEL

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 4.750 (120.650) 4.125 (104.775) 3.125 (79.375) 2.900 (73.66) 2.320 (58.928)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10) CIV CIV
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 4.125 (104.775) 3.125 (79.375) 2.625 (66.675) 2.900 (73.66) 2.320 (58.928)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10) CIV CIV
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4)
TORQUE–DRY FT–LB (Nm) 700 (950) 700 (950) 700 (950) 700 (950) 700 (950)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 3/4–10 (19.05) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4)
TORQUE–DRY FT–LB (Nm) 90 (122) 300 (407) 700 (950) 700 (950) 700 (950)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 1–1/8–7 (28.5) 1–1/8–7 (28.5) 1–8 (25.4) N/A N/A
TORQUE–DRY FT–LB (Nm) 1000 (1355) 1000 (1355) 700 (950)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A 1–1/4–7 (31.75) 1–1/4–7 (31.75)
TORQUE–DRY FT–LB (Nm) 1360 (1845) 1360 (1845)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) 3/4–10 (19.0) 7/8–9 (22.2) 3/4–10 (19.05) 3/4–10 (19.05) 3/4–10 (19.05)
TORQUE–DRY FT–LB (Nm) 260 (352) 430 (583) 260 (352) 380 (515) 380 (515)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A N/A N/A
Page 56

TORQUE–DRY FT–LB (Nm)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A 1/2–13 (12.7) 1–1/4–7 (31.75) 1–1/4–7 (31.75)
TORQUE–DRY FT–LB (Nm) 75 (101) 1360 (1845) 1360 (1845)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) 3/4–10 (19.05) 5/8–11 (15.88) 3/4–10 (19.05) 5/8–11 (15.88) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 260 (352) 150 (203) 260 (352) 220 (298) 110 (149)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 3/8–16 (9.5) N/A N/A
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27) 15 (20)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) N/A N/A
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) N/A N/A
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.5) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 50 (67) 50 (67) 50 (67) 50 (67) 50 (67)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (101) 75 (101) 75 (101) 75 (101) 75 (101)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (101) 75 (101) 75 (101) 75 (101) 75 (101)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) 1–3/8–8 (34.9) 1–3/8–8 (34.9) 1–3/8–8 (34.9) 1–3/8–8 (34.9) 1–3/8–8 (34.9)
TORQUE–DRY FT–LB (Nm) 150–200 (204–271) 150–200 (204–271) 150–200 (204–271) 150–200 (204–271) 150–200 (204–271)
 PUMP DATA SHEET
MODEL: TDE (GD180T)

SPECIFICATIONS:
MAXIMUM HORSEPOWER: 180 HP (134 kW) MAXIMUM PLUNGER LOAD: 11560 LB (5242 Kg)
MAXIMUM CRANKSHAFT RPM: 370 RPM CRANKSHAFT EXTENSION:
MINIMUM CRANKSHAFT RPM: 175 RPM DIAMETER: 4.00 IN. (101.6 mm)
STROKE: 5.00 IN. (127 mm) LENGTH: 8.00 IN. (202 mm)
NUMBER OF PLUNGERS: 3 KEYWAY (L x W x H): 7–1/8 x 1 x 1
TYPE OF LUBRICATION: SPLASH PUMP WEIGHT: 3032 LB (1375 Kg) APPROXIMATE
OIL CAPACITY: 14.5 GAL. (55 LITERS)

STANDARD FLUID CYLINDERS:

Max Plunger Min Plunger

Size Pressure Size Pressure
In. PSI In. PSI Standard Connections
Description (mm) (Kg/Cm2) (mm) (Kg/Cm2) Suction Discharge

TDEA – LP ALUMINUM BRONZE 4–1/4 815 3 1635 6”–150# 3”–2000#

(TAPERED SEAT VALVES) (108) (57) (76) (115) ANSI API RJ
FLANGE FLANGE

TDEB – MP ALUMINUM BRONZE 3 1635 2 3680 4”–150# 2”–1500#

(TAPERED SEAT VALVES) (76) (115) (51) (259) ANSI ANSI
FLANGE FLANGE

TDEC – HP BLOCK STEEL 2 3680 1–1/4 9415 3”–300# 1–13/16” API

(TAPERED SEAT VALVES) (54) (259) (32) (662) ANSI 10000# RJ
FLANGE FLANGE

TDEF – HP BLOCK STEEL 2 3680 1–1/4 7500 3”–3000# (4) 3/4” Bolts
(CLAMPED IN VALVES) (54) (259) (32) (528) SAE 4 Bolt 4.50 DBC
FLANGE SPECIAL

TDEG – STEEL–EXTRA HIGH 1–1/2 6535 1 12000 2”–3000# (4) 3/4” Bolts
PRESSURE BLOCK (38) (459) (25) (842) SAE 4 Bolt 4.50 DBC
(CLAMPED IN VALVES) FLANGE SPECIAL

3–1–614 Page 57
 REBUILDING DATA FOR TDE (GD180T) PUMPS

PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDE (GD180T) TDE (GD180T)

PUMP STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IN. 127 mm

INCHES METRIC (mm)

Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.998/4.999 126.949/126.975

Crankpin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.504/3.515 89.002/89.281
Crankshaft Diameter at Main Bearing . . . . . . . . . . . . . . . . 4.2515/4.2525 107.9881/108.0135
Distance Between Main Bearings . . . . . . . . . . . . . . . . . . . . 21.875/21.885 555.625/555.879
Bore in Housing for Main Bearing . . . . . . . . . . . . . . . . . . . 8.373/8.375 212.674/212.725
Connecting Rod Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0625 331.7875
Bore in Connecting Rod for Crosshead Pin . . . . . . . . . . . 3.000/3.002 76.200/76.251
Bore in Connecting Rod for Insert . . . . . . . . . . . . . . . . . . . 5.224/5.225 132.690/132.715
Crosshead Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0000/3.0005 76.2000/76.2127
Crosshead Pin Bushing Bore (Honed) . . . . . . . . . . . . . . . 3.0015/3.0020 76.2381/76.2508
Bore in Crosshead for Bushing . . . . . . . . . . . . . . . . . . . . . . 3.374/3.375 85.699/85.725

RUNNING CLEARANCES – ACTUAL*:

Crankpin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0022/.0056 .0559/.1422

Crankpin Bearing Width Clearance . . . . . . . . . . . . . . . .007/.023 .178/.584
Crosshead Pin to Bushing . . . . . . . . . . . . . . . . . . . . . . .0010/.0020 .0254/.0508
Main Bearing End Clearance . . . . . . . . . . . . . . . . . . . . .002/.004 .051/.102
Crosshead to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .006/.011 .152/.279

* Feeler gauge clearances .001 inch or .025 mm less than actual values.

3–1–614 Page 58
 TDE (GD180T)
MODEL TDEA TDEB TDEC TDEF TDEG
DESCRIPTION LP ALUMINUM BRONZE MP ALUMINUM BRONZE HP BLOCK STEEL HP BLOCK STEEL XHP BLOCK STEEL

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 4.750 (120.650) 4.125 (104.775) 3.125 (79.375) 2.900 (73.66) 2.320 (58.928)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10) CIV CIV
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 4.125 (104.775) 3.125 (79.375) 2.625 (66.675) 2.900 (73.66) 2.320 (58.928)
GAGE DIAMETER – IN/FT (mm) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10) CIV CIV
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4)
TORQUE–DRY FT–LB (Nm) 700 (950) 700 (950) 700 (950) 700 (950) 700 (950)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 3/4–10 (19.05) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4)
TORQUE–DRY FT–LB (Nm) 90 (122) 300 (407) 700 (950) 700 (950) 700 (950)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 1–1/8–7 (28.5) 1–1/8–7 (28.5) 1–8 (25.4) N/A N/A
TORQUE–DRY FT–LB (Nm) 1000 (1355) 1000 (1355) 700 (950)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A 1–1/4–7 (31.75) 1–1/4–7 (31.75)
TORQUE–DRY FT–LB (Nm) 1360 (1845) 1360 (1845)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) 3/4–10 (19.05) 7/8–9 (22.2) 3/4–10 (19.05) 3/4–10 (19.05) 3/4–10 (19.05)
TORQUE–DRY FT–LB (Nm) 260 (352) 430 (583) 260 (352) 380 (515) 380 (515)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A N/A N/A
Page 59

TORQUE–DRY FT–LB (Nm)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A 1/2–13 (12.7) 1–1/4–7 (31.75) 1–1/4–7 (31.75)
TORQUE–DRY FT–LB (Nm) 75 (101) 1360 (1845) 1360 (1845)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) 3/4–10 (19.05) 5/8–11 (15.88) 3/4–10 (19.05) 5/8–11 (15.88) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 260 (352) 150 (203) 260 (352) 220 (298) 110 (149)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 3/8–16 (9.5) N/A N/A
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27) 15 (20)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) N/A N/A
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) N/A N/A
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 50 (67) 50 (67) 50 (67) 50 (67) 50 (67)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (101) 75 (101) 75 (101) 75 (101) 75 (101)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (101) 75 (101) 75 (101) 75 (101) 75 (101)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) 1–3/8–8 (34.9) 1–3/8–8 (34.9) 1–3/8–8 (34.9) 1–3/8–8 (34.9) 1–3/8–8 (34.9
TORQUE–DRY FT–LB (Nm) 150–200 (204–271) 150–200 (204–271) 150–200 (204–271) 150–200 (204–271) 150–200 (204–271)
 PUMP DATA SHEET
MODEL: TFE (GD200T)

SPECIFICATIONS:
MAXIMUM HORSEPOWER: 205 HP (153 kW) MAXIMUM PLUNGER LOAD: 13182 LB (5979 Kg)
MAXIMUM CRANKSHAFT RPM: 370 RPM CRANKSHAFT EXTENSION:
MINIMUM CRANKSHAFT RPM: 175 RPM DIAMETER: 4.00 IN. (101.6 mm)
STROKE: 5.00 IN. (127 mm) LENGTH: 8.00 IN. (202 mm)
NUMBER OF PLUNGERS: 3 KEYWAY (L x W x H): 7–1/8 x 1 x 1
TYPE OF LUBRICATION: SPLASH PUMP WEIGHT: 3032 LB (1375 Kg) APPROXIMATE
OIL CAPACITY: 14.5 GAL. (55 LITERS)

STANDARD FLUID CYLINDERS:

Max Plunger Min Plunger

Size Pressure Size Pressure
In. PSI In. PSI Standard Connections
Description (mm) (Kg/Cm2) (mm) (Kg/Cm2) Suction Discharge

TFEA – LP ALUMINUM BRONZE 4–1/4 930 3 1865 6”–150# 3”–2000#

(TAPERED SEAT VALVES) (108) (65) (76) (131) ANSI API RJ
FLANGE FLANGE

TFEB – MP ALUMINUM BRONZE 3 1865 2 3705 4”–150# 2”–1500#

(TAPERED SEAT VALVES) (76) (131) (51) (260) ANSI ANSI
FLANGE FLANGE

TFEC – HP BLOCK STEEL 2 4190 1–1/4 10000 3”–300# 1–13/16” API

(TAPERED SEAT VALVES) (54) (295) (32) (703) ANSI 10000# RJ
FLANGE FLANGE

TFEF – HP BLOCK STEEL 2 4190 1–1/4 7500 3”–3000# (4) 3/4” Bolts
(CLAMPED IN VALVES) (54) (295) (32) (528) SAE 4 Bolt 4.50 DBC
FLANGE SPECIAL

TFEG – STEEL–EXTRA HIGH 1–1/2 7445 1 12000 2”–3000# (4) 3/4” Bolts
PRESSURE BLOCK (38) (523) (25) (842) SAE 4 Bolt 4.50 DBC
(CLAMPED IN VALVES) FLANGE SPECIAL

3–1–614 Page 60
 REBUILDING DATA FOR TFE (GD200T) PUMPS

PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TFE (GD200T) TFE (GD200T)

PUMP STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IN. 127 mm

INCHES METRIC (mm)

Crankpin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.495/5.496 139.573/139.598

Crankpin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.504/3.515 89.002/89.281
Crankshaft Diameter at Main Bearing . . . . . . . . . . . . . . . . 4.2515/4.2525 107.9881/108.0135
Distance Between Main Bearings . . . . . . . . . . . . . . . . . . . . 21.875/21.885 555.625/555.879
Bore in Housing for Main Bearing . . . . . . . . . . . . . . . . . . . 8.373/8.375 212.674/212.725
Connecting Rod Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0625 331.7875
Bore in Connecting Rod for Crosshead Pin . . . . . . . . . . . 3.000/3.002 76.200/76.251
Bore in Connecting Rod for Insert . . . . . . . . . . . . . . . . . . . 5.752/5.753 146.100/146.126
Crosshead Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0000/3.0005 76.2000/76.2127
Crosshead Pin Bushing Bore (Honed) . . . . . . . . . . . . . . . 3.0015/3.0020 76.2381/76.2508
Bore in Crosshead for Bushing . . . . . . . . . . . . . . . . . . . . . . 3.374/3.375 85.699/85.725

RUNNING CLEARANCES – ACTUAL*:

Crankpin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0046/.0080 .1168/.2032

Crankpin Bearing Width Clearance . . . . . . . . . . . . . . . .007/.023 .178/.584
Crosshead Pin to Bushing . . . . . . . . . . . . . . . . . . . . . . .0010/.0020 .0254/.0508
Main Bearing End Clearance . . . . . . . . . . . . . . . . . . . . .002/.004 .051/.102
Crosshead to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .006/.011 .152/.279

* Feeler gauge clearances .001 inch or .025 mm less than actual values.

3–1–614 Page 61
 TFE (GD200T)
MODEL TFEA TFEB TFEC TFEF TFEG
DESCRIPTION LP ALUMINUM BRONZE MP ALUMINUM BRONZE HP BLOCK STEEL HP BLOCK STEEL XHP BLOCK STEEL

DISCHARGE VALVE SEAT

GAGE DIAMETER – IN (mm) 4.750 (120.650) 4.125 (104.775) 3.125 (79.375) 2.900 (73.66) 2.320 (58.928)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10) CIV CIV
SUCTION VALVE SEAT
GAGE DIAMETER – IN (mm) 4.125 (104.775) 3.125 (79.375) 2.625 (66.675) 2.900 (73.66) 2.320 (58.928)
GAGE DIAMETER – IN/FT (mm/M) 1.50 (38.10) 1.50 (38.10) 1.50 (38.10) CIV CIV
FLUID CYLINDER TO FRAME NUTS
THREAD SIZE – IN (mm) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4)
TORQUE–DRY FT–LB (Nm) 700 (950) 700 (950) 700 (950) 700 (950) 700 (950)
STUFFING BOX TO FLUID NUTS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 3/4–10 (19.05) 1–8 (25.4) 1–8 (25.4) 1–8 (25.4)
TORQUE–DRY FT–LB (Nm) 90 (122) 300 (407) 700 (950) 700 (950) 700 (950)
DISCHARGE VALVE COVER NUTS
THREAD SIZE – IN (mm) 1–1/8–7 (28.5) 1–1/8–7 (28.5) 1–8 (25.4) N/A N/A
TORQUE–DRY FT–LB (Nm) 1000 (1355) 1000 (1355) 700 (950)
DISCHARGE MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A 1–1/4–7 (31.75) 1–1/4–7 (31.75)
TORQUE–DRY FT–LB (Nm) 1360 (1845) 1360 (1845)
3–1–614

DISCHARGE FLANGE FASTENERS

THREAD SIZE – IN (mm) 3/4–10 (19.05) 7/8–9 (22.2) 3/4–10 (19.05) 3/4–10 (19.05) 3/4–10 (19.05)
TORQUE–DRY FT–LB (Nm) 260 (352) 430 (583) 260 (352) 380 (515) 380 (515)
SUCTION VALVE COVER NUTS
THREAD SIZE – IN (mm) N/A N/A N/A N/A N/A
Page 62

TORQUE–DRY FT–LB (Nm)

SUCTION MANIFOLD TO CYLINDER NUTS
THREAD SIZE – IN (mm) N/A N/A 1/2–13 (12.7) 1–1/4–7 (31.75) 1–1/4–7 (31.75)
TORQUE–DRY FT–LB (Nm) 75 (101) 1360 (1845) 1360 (1845)
SUCTION FLANGE FASTENERS
THREAD SIZE – IN (mm) 3/4–10 (19.05) 5/8–11 (15.88) 3/4–10 (19.05) 5/8–11 (15.88) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 260 (352) 150 (203) 260 (352) 220 (298) 110 (149)
PLATE OR DISC TYPE VALVES –
RETAINER TO SEAT FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 3/8–16 (9.5) N/A N/A
TORQUE–DRY FT–LB (Nm) 20 (27) 20 (27) 15 (20)
WING–GUIDED VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) N/A N/A
SEVERE DUTY VALVES–CAGE TO SEAT
TORQUE–DRY FT–LB (Nm) 40 (54) 40 (54) 40 (54) N/A N/A
PLUNGER COUPLING FASTENER
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 50 (67) 50 (67) 50 (67) 50 (67) 50 (67)
CONNECTING ROD CAP FASTENERS
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (101) 75 (101) 75 (101) 75 (101) 75 (101)
CONNECTING ROD PINCH BOLT
THREAD SIZE – IN (mm) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7) 1/2–13 (12.7)
TORQUE–DRY FT–LB (Nm) 75 (101) 75 (101) 75 (101) 75 (101) 75 (101)
EXTENSION ROD TO CROSSHEAD
THREAD SIZE – IN (mm) 1–3/8–8 (34.9) 1–3/8–8 (34.9) 1–3/8–8 (34.9) 1–3/8–8 (34.9) 1–3/8–8 (34.9)
TORQUE–DRY FT–LB (Nm) 150–200 (204–271) 150–200 (204–271) 150–200 (204–271) 150–200 (204–271) 150–200 (204–271)
 FASTENER TORQUES
UNLESS OTHERWISE SPECIFIED
ALL PUMPS (GRADE 5)

THREAD SIZE TORQUE DRY

INCHES mm FT. LB. Nm

3/8 – 16 9.5 30 40

1/2 – 13 12.7 75 102

9/16 – 12 14.3 110 149

5/8 – 11 15.8 150 203

3/4 – 10 19.0 260 352

7/8 – 9 22.2 430 583

1–8 25.4 640 867

1–1/8 – 7 28.6 800 1084

1–1/4 – 7 31.8 1120 1518

3–1–614 Page 63
 WARRANTY
GARDNER DENVERR D OPIR PUMPS

GENERAL PROVISIONS AND LIMITATIONS Labor shall be limited to the amount specified in the
Company’s labor rate schedule.
Gardner Denver Machinery Inc. (the “Company”) war-
rants to each original retail purchaser (“Purchaser”) of its Labor costs in excess of the Company rate schedules
new products from the Company or its authorized distrib- caused by, but not limited to, location or inaccessibility
utor that such products are, at the time of delivery to the of the equipment, or labor provided by unauthorized ser-
Purchaser, made with good material and workmanship. vice personnel is not provided for by this warranty.
No warranty is made with respect to: All costs of transportation of product or parts claimed not
1. Any product which has been repaired or altered to be as warranted and, of repaired or replacement parts
in such a way, in the Company’s judgment, as to to or from such service facility shall be borne by the Pur-
affect the product adversely. chaser. The Company may require the return of any part
claimed not to be as warranted to one of its facilities as
2. Any product which has, in the Company’s judg- designated by the Company, transportation prepaid by
ment, been subject to negligence, accident, im- the Purchaser, to establish a claim under this warranty.
proper storage, or improper installation or ap-
plication. Replacement parts provided under the terms of this war-
ranty are warranted for the remainder of the Warranty
3. Any product which has not been operated or Period of the product upon which installed to the same
maintained in accordance with the recommen- extent as if such parts were original components.
dations of the Company.
WARRANTY REGISTRATION VALIDATION
4. Components or accessories manufactured,
warranted and serviced by others. A warranty registration form is provided with each ma-
chine. The form must be completed by the Purchaser
5. Any reconditioned or prior owned product. and mailed within ten days after machine start–up to vali-
date the warranty.
Claims for items described in (4) above should be sub-
mitted directly to the manufacturer. DISCLAIMER
WARRANTY PERIOD THE FOREGOING WARRANTY IS EXCLUSIVE AND
IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO
The Company’s obligation under this warranty is limited TITLE, THE COMPANY MAKES NO OTHER WAR-
to repairing or, at its option, replacing, during normal RANTIES, EXPRESSED, IMPLIED OR STATUTORY,
business hours at an authorized service facility of the INCLUDING ANY IMPLIED WARRANTY OF MER-
Company, any part which in its judgment proved not to CHANTABILITY.
be as warranted within the applicable Warranty Period
as follows. THE REMEDY PROVIDED UNDER THIS WARRANTY
SHALL BE THE SOLE, EXCLUSIVE AND ONLY REM-
Except for the products or components listed below, the EDY AVAILABLE TO PURCHASER AND IN NO CASE
Warranty Period for all products is 1,250 hours of opera- SHALL THE COMPANY BE SUBJECT TO ANY
tion or three (3) months after start–up, not to exceed 120 OTHER OBLIGATIONS OR LIABILITIES. UNDER NO
days after delivery to Purchaser, whichever occurs first. CIRCUMSTANCES SHALL THE COMPANY BE
The exceptions are as follows: LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL
1. Power end is warranted for twelve (12) months OR CONSEQUENTIAL DAMAGES, EXPENSES,
from date of start–up or eighteen (18) months LOSSES OR DELAYS HOWSOEVER CAUSED.
from date of delivery to the Purchaser, whichev- No statement, representation, agreement, or under-
er occurs first. standing, oral or written, made by any agent, distributor,
2. Forged steel fluid cylinder is warranted for 90 representative, or employee of the Company which is
days from date of installation. not contained in this Warranty will be binding upon the
Company unless made in writing and executed by an of-
3. Expendable fluid end parts, including, but not ficer of the Company.
limited to, valves, valve parts, packing, liners
and pistons, are not covered by this warranty This warranty shall not be effective as to any claim which
due to variable abrasive nature of material is not presented within 30 days after the date upon which
pumped. the product is claimed not to have been as warranted.
Any action for breach of this warranty must be com-
LABOR TRANSPORTATION AND INSPECTION menced within one year after the date upon which the
The Company will provide labor, by Company represen- cause of action occurred.
tative or authorized service personnel, for repair or re- Any adjustment made pursuant to this warranty shall not
placement of any product or part thereof which in the be construed as an admission by the Company that any
Company’s judgment is proved not to be as warranted. product was not as warranted.

BE–13 R 10/96